储罐水压试验方案

塞拉尼斯（南京）乙酰基中间体有限公司工业乙醇项目
Celanese China Fast Project
文件类型Document type 文件页数
Pages
版次
Version
修订说明
Revision
note
受控编号
Controlled number
GH 20 1版
Version1 首次1st
储罐充水试压方案
Tank Hydro-test Plan
2 2012年11月1日
Nov. 1, 2012
版次Edition 日期
Date
编制
Formulated
by
审核
Reviewed by
批准
Approved by
中国化学工程第十三建设有限公司
The 13th Construction Co., Ltd. of CNCE
储罐充水试压方案
Tank Hydro-test Plan
目录Contents
一适用范围Range of Application (2)
二编制依据Formulation Basis (2)
三工程概况General (2)
四施工工序Construction Procedure (3)
五施工步骤及方法Construction Procedure and Method (4)
5.1 检查内容Check the contents： (4)
5.2 准备工作Preparatory work： (4)
5.3 充水试验应符合下列规定The hydro-test shall be in compliance with following regulations (5)
5.4 水压试验示意图Hydro-test Diagram (6)
5.5 充水过程检查Inspection for Water Filling Process (7)
5.6 充水试验方法Hydro-test method (8)
5.7 基础沉降观测Foundation Settlement Observation (10)
5.8放水检查Inspection for Water Draining (12)
5.9试压技术要求Technical Requirements for Pressure Test (13)
六质量管理Quality Management (13)
6.1 质量保证体系Quality Guarantee Measures： (13)
6.2 质量保证措施Quality Guarantee Measures： (14)
七质量管理Quality Management (15)
7.1 安全保证体系Safety assurance system： (15)
7.2 安全保证措施计划Planning for safety assurance measures： (16)
八人力计划VII. Planning for Labor Forces (18)
九机具准备VII. Preparations of Machines and Tools (18)
十工作危险源分析评估及预防Work-related Hazard Analysis Evaluation and Prevention (19)
一．适用范围Range of Application
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。

This plan is applicable to the execution of the hydro-test for 4 tanks in the modification and expansion of the tank farm of Celanese China Fast Project.
二．编制依据Formulation Basis
1) 《钢制焊接常压容器》Steel Welded Atmospheric Pressure Vessels JB/T4735-1997
2) 《立式圆筒形钢制焊接油罐施工及验收规范》Code for Construction and Acceptance of Welded
Steel Oil Tank of V ertical Barrel Shape GB50128-2005
3) 《石油化工钢储罐地基与基础施工及验收规范》Specification for Construction and Acceptance of
Steel Storage Tank Subgrade & Foundation in Petrochemical Industry S H3528-93
4) 《大型焊接低压储罐设计与建造》Design and Construction of Large, Welded, Low-pressure Storage
Tanks API620-2009
5) 塞拉尼斯技术要求及相关过程规定Celanese technical requirements and related process regulations 三．工程概况General
四．施工工序Construction Procedure
五．施工步骤及方法Construction Procedure and Method
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。

Before the hydro-test, the tank shell shall be jointly inspected. After NTD of the tank shell, and all fittings and accessories are installed, tested, inspected and accepted, clean the tank inside and close the manhole, fill water and take the hydro-test. During water filling, the hydro-test requirements shall be combined with the civil structure foundation settlement observation, personnel shall be specially assigned for monitoring the filling and draining time, any abnormality shall be treated in time, no water can be filled in before the treatment is accepted. After completion of the hydro-test, the water in the tank shell shall be promptly drained according to the owner’s requirements and the location for draining.
5. 1储罐制造完毕后，进行充水试验，并检查下列内容：Hydro-test will be taken after the tank is finished in fabrication, and the following content
shall be checked:
1）罐底严密性。

Tightness of the tank bottom
2）罐壁强度及严密性。

Strength and tightness of the tank shell
3）固定顶的强度及严密性。

Strength and tightness of the fixed roof
4）固定顶的稳定性。

Stability of the fixed roof
5）基础的沉降观测。

Settlement observation for the foundation
5.2压力试验前，首先做好以下准备工作：The following preparations shall be made before the pressure test:
1）检查罐外形尺寸、附件安装是否符合要求。

Check if the tank outline dimension and accessory installation satisfy requirements.
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。

Before water filling, clean out sundries in the tank and close it, close the nozzle on the tank shell with temporary blind, and close the manhole with the manhole flange.
3）检查罐管口、法兰是否已焊接完，是否有漏焊部位。

Check if the tank nozzle and flange are finished in welding, and if the welding on any part is missed.
4）接管补强圈用压缩空气气密工作已做完，且合格。

The airtight work of the compressed air used for the nozzle reinforcing ring has been completed and qualified.
5）水源采用消防储罐的低压消防水，压力为1.5Mpa。

The water is sourced from the low pressure fire water of the fire tank, and the pressure is 1.5Mpa.
6）沉降观测，储罐选定4个沉降观测点。

Settlement observation: 4 settlement observation points are selected for tanks.
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。

Set up settlement observation points and reference points before water filling for the tank, and measure the elevation of every measuring point when the water level is 0.
8）碳钢储罐试验应采用洁净水，试验用水温不低于5℃。

The CS tank test shall adopt clean water,
and the water temperature used for the test shall not be lower than 5℃.
9）V-737不锈钢储罐试验用水氯离子含量不得超过25mg/L。

The content of the chloride ion in water used for V-737 SS tank test shall not be more than 25mg/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。

Set up the settlement observation point and the reference point before water filling for the tank, and measure the elevation of every measuring point when the water level is 0.
5.3充水试验应符合下列规定：The hydro-test shall be in compliance with following regulations:
1）充水和放水过程中，打开放空孔，基础避免浸水。

During water filling and draining, open the 2）充水时严格控制上水、停水的进程，随时检查水位。

During water filling, strictly control the process of water filling and water cutoff, and check the water level any time.
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。

When the hydro-test is taken for the first tank, the water shall be quickly filled to the point of 1/2 of the tank height during water filling, observe the settlement, when the unequal settlement is still less than 5mm/day, go on filling in water to the point of 3/4 of the tank height for observation; when the unequal settlement is still less than 5mm/day, go on filling in water to the highest operating level, and observe it after maintaining 48hrs, if the settlement doesn’t obviously change, the water can be drained, if the settlement obviously changes, keep the highest operating level, and observe it regularly every day, until the settlement is steady.
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。

After the foundation settlement of the first tank meets requirements, when the hydro-test is taken for the rest tanks, the settlement will be observed twice respective at the point of 1/2 and 3/4 height of the tank.
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)Allowable value of the tank foundation settlement (equal settlement value)
Reference valve:
Allowable value of the tank foundation settlement (equal settlement value) Attached table 1
Floating roof tank and inner floating roof tank Fixed roof tank
Inside diameter of tank
D(m) Allowable value of the
final settlement
difference in any
diametrical direction
Inside diameter of tank
D(m)
Allowable value of the
final settlement
difference in any
diametrical direction
5.4水压试验示意图：Hydro-test Diagram
临时管线接入口Temporary pipe access
φ108*6
φ108*6
消防带fire hose Φ108×6
阀1 储罐tank
另一台储罐
another tank
污水井drain well
阀Valve 4
阀Valve 3
压力表pressure gauge
●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；Connect the temporary pipe (φ108*6) to the access of the tank foam
descending groove at the temporary access of foam fire-proof in the tank farm.
●按上图所示建立试压系统；Establish the pressure test system according to the
above diagram.
5.5充水过程检查：Inspection for Water Filling Process
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
The secure water when the inlet valve, strict control of water the size of, at the
same time to find someone through the U-meter Observe the the tanks actual
charge water and influent personnel with the process for the liquid level of the
liquid level → 1/2 3/4Height -1 m → → full of water full of water height
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。

Do intensify settlement observation during the hydro-test, if unallowable settlement arises from the foundation, the water filling shall top, and do not go on the test before treatment.
3）充水和放水过程中应打开罐顶人孔Do open the manhole on the tank roof during the process of water filling and draining.
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。

Do control the flow speed of water during water filling, and the speed of water surface ascent shall not exceed 0.9m/h.
5)上水过程中在最高设计液位的50%和75%进行罐体检查。

During water filling, check the tank body at the point of 50% and 75% of the highest design level.
5.6充水试验方法：Hydro-test method:
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。

Tightness of the tank bottom: if the tank has no leakage during the hydro-test, it is acceptable, in case of any leakage, it shall be inspected and welding-repaired after water draining.
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。

Strength and tightness test for the tank shell: if the tank shell is free of leakage, abnormality and deformation after the water is filled to the highest design level and maintains 48h, it is acceptable, in case of any leakage, the water shall be drained to make the water level 300mm lower than the leakage.
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;Strength and tightness test of the fixed roof: open Valve 1, close Valve 2, and fill water from the tank top through the fire hose, when the water is filled to the point of 1m lower than the design level, block all openings by blinds, slowly regulate Valve 1, the pressure slowly rises, when the pressure rises to the test pressure
(0.12Mpa), stop filling water, and conduct the strength and tightness test for the fixed
roof, apply soapy water on the tank roof for inspection, and do open the tank roof hole immediately after the test, so as to contact the atmosphere and recover to normal pressure.
4）固定顶的稳定性试验，充水到设计最高液位时，用盲板封堵所有开孔，打开阀门4、3，用放水方法进行固定顶的稳定性试验，缓慢降压，达到试验负压（-0.00162Mpa）时，观察罐顶（罐顶无异常变形为合格），试验后应立即将孔开启,与大气相通，恢复到常压;固定顶储罐在充水到8754mm液位前，应打开顶部人孔。

Stability test for the fixed roof: when the water is filled to the highest design level, block all openings with blinds, open Valve 3 and Valve 4, conduct the stability test of the fixed roof by water draining, depressurized it slowly, when it is up to the test negative pressure (-0.00162Mpa), observe the tank roof (it is acceptable if the tank roof is free of abnormality and deformation), do open the hole immediately after the test, so as to contact the atmosphere and recover to normal pressure. The roof
manhole shall be opened before the water in the fixed roof tank is filled to the level 8754mm.
5）当考虑水的重复利用，第一台罐水压试验完毕后，缓慢打开阀3，将水直接排到第二台罐里，待两罐水位平衡后，关闭阀2，然后利用消防带进行上水；In view of recycling of water, after the first tank is finished in the hydro-test, slowly open Valve 3, directly drain the water to the second tank, after the water level in the two tanks is balanced, close Valve 2, and then fill water with the fire hose.
5.7基础沉降观测Foundation Settlement Observation
1）根据储罐的体积和直径，确定储罐沉降观测的点数，见下图。

Make sure the number of tank settlement observation points according to the volume and diameter of the tank, see the following drawing.
2）四台储罐分别选好基准点为控制点。

Reference points are respectively selected for the four tanks as control points.
3) 空罐（上水前，第一次）→1/2液位高度（第二次）→3/4液位高度（第三次）→满水高度（1小时第四次）→满水高度-1米（第五次）→满水高度（48小时后，第六次）→空罐（放水后，第七次）
Empty tank (before water filling, the first time) →1/2 water level (the second time) →3/4 water level (the third time) →full water level (1hr, the fourth time)→full water level (after 48hrs, the fifth time)
→empty(after water draining, the sixth time)
4) 水压试验过程中，应紧密跟踪罐体每次的沉降量，检查其是否符合规范允许值。

During the hydro-test, closely track the settlement of the tank body every time, and check if they satisfy the specified allowable value.
5）储罐基础沉降允许值：充水高度为：H/2（H为罐高），沉降量<5mm/d,充水高度为：3H/4，沉降量仍<5mm/d,充水到最高液位后，保持48h观测，总沉降量<25mm.Allowable value of the tank foundation settlement: the water filling level: H/2 (H is the height of the tank), the settlement <5mm/d, the water filling height is 3H/4, the settlement<5mm/d, after the water is filled to the highest level, observe it for 48h, and the total settlement <25mm.
6)为方便测出罐内液位的实际高度，从罐壁管口上接出一临时阀门，并将软管接从低接管接到罐顶，为防止塑胶管滑落，采用柔性材料将其临时绑扎到脚手架靠里侧。

In order to measure the actual height of the water level in the tank, extend a temporary valve from the tank nozzle, and connect the hose to the tank roof from the lower nozzle, in order to prevent plastic pipe from sliding, bind it to the inner side of the scaffold temporarily with flexible material.
5.8放水检查Inspection for Water Draining
1) 放水停留时间应符合土建专业设计文件的要求Water draining detention time shall be in
compliance with the requirements of design documents of the civil work discipline.
2) 储罐试压完毕后，放水应排放到指定位置（罐区围堰内部排水沟），不可就地排放使基
础浸水；After the tank pressure test is finished, the water shall be drained to the specified position, and cannot be drained locally for fear of foundation soaking.
3）罐内应彻底地进行清扫，除去锈蚀，底板不应有显著的变形和明显凸凹，各附件应符合图样要求，且无异常现象。

The tank shall be completely cleaned, rust shall be removed, and bottom plates shall be free of significant deformation and obvious unevenness, all accessories shall be in compliance with drawing requirements, and be free of any abnormality.
4）放水后及时将罐内的积水和杂物清扫干净，应打开所有的管口和人孔，以加强罐内的空气流通，当罐内水吹干后，及时检查，并用抹布清除干净罐内的水渍。

Clean up accumulated water and sundries in the tank in promptly after water draining, all nozzles and manholes shall be opened, so as to strengthen ventilation in the tank, after the water in the tank is dried, inspect it in time and remove water stain in the tank with rags.
5.9试压技术要求Technical Requirements for Pressure Test
1.一般要求general requirements
1）试压工作开战前，施工技术人员必须对参加试压的所有人员进行技术交底，安全交底，严格遵守安全纪律和操作规程。

Before start of the pressure test, technical personnel of construction shall give technical and safety presentation to all pressure test participants, and abide by safety disciplines and operating regulations strictly.
2）划定危险区，并安排人员负责警戒，禁止无关人员进入。

Divide dangerous zones, and arrange persons to be responsible for alert, and no entry for unrelated personnel.
2.试验时的要求test requirements
1）水压试验时，严禁对罐身、接口进行敲打或修补缺陷，严禁带压修理，泄压后再进行修补，缺陷消除后重新试压。

During the hydro-test, neither knock the tank body or nozzle nor repair defects, repair with pressure is prohibited, and no repair before pressure release, repeat the pressure test after removal of defects.
2）罐顶稳定性试验时，确保安全装置良好。

During the stability test for the tank roof, ensure the safety device is good.
3）负责降压的操作人员必须控制升压的速度，进水，泄压注意防空。

Operators who are responsible for reducing pressure must control the speed of boosting pressure, water inflow and pressure relief, and pay attention not to emptying.
4）水压试验后，试压用水必须由管道排放至指定地点，不得就地排放。

After the hydro-test, the water used for pressure test shall be drained to the specified location through the pipe, do not drain it locally.
6. 质量管理Quality Management
6.1 质量保证体系Quality Guarantee Measures
1 项目经理部质量保证体系见施工组织设计。

For the quality guarantee system of
the project manager department, see the construction organization design please.
2 作业层质量保证体系。

Quality guarantee system of the operation level
↓
↓
↓
↓
6.2 质量保证措施Quality Guarantee Measures
1)试验时每台储罐应装设1块压力表，1块真空表，试验压力以装设在设备最高处的压力表读数为准。

During the test, each tank shall be provided with one pressure gauge and one vacuum gauge, and the test pressure shall be based on the reading of the pressure gauge mounted on the highest point of
the equipment.
2)压力表须经校准，精度不低于1.5级，量程为最大被测压力的1.5~3倍。

The pressure gauge should be calibrated, the precision shall not be lower than Grade1.5, and the measuring range is 1.5~3 times of the greatest pressure measured.
3)有专人看护压力表，严禁超过规定的试验压力。

Personnel shall be specially assigned to watch the pressure gauge, the test pressure against regulations is forbidden. 4)严格控制上水、进水、放水的过程，以避免超压或抽空。

Strictly control the process of water filling, water inflow and water draining, so as to avoid overpressure or emptying.
七． 安全管理 X Safety Management
7.1 安全保证体系Safety assurance system
7.1.1项目经理部安全保证体系见施工组织设计；For the safety assurance system of the project manager department, see the construction organization design please. 7.1.2作业层安全保证体系；Safety assurance system of the operation level
↓
↓
←
↓
↓
7.2 安全保证措施计划Planning for safety assurance measures
7.2.1一般要求：General requirements:
1 压力试验的各项准备工作必须经过我方质量部门的自检合格，安全工作经过
HSE经理同意后方可开始进行试压工作。

All preparations for the pressure test
shall be self-inspected by our quality department and acceptable, and the pressure
test cannot be conducted before the safety work is approved by HSE manager.
2 所有参与压力试验人员要进行岗位分工，责任明确；All pressure test participants’
duty shall be divided with clear responsibility.
3 试压时用警戒绳将储罐圈出安全范围，无关人员不得擅自靠近，以防止突发事
故。

During the pressure test, the alert rope shall be used to ring the safety range of
the tank, and unrelated personnel shall not approach without authorization.
4 试压时随时注意环境温度的变化，监视压力表的读数，防止发生超压现象。

During the pressure test, pay attention to the variation of the ambient temperature
any time, so as to avoid overpressure.
5 试压过程中，如发现有异常响声、压力下降或加压装置发生故障灯不正常现象
时，应立即停止试验，并查明原因。

During the pressure test, in case of any
abnormal noise, pressure drop or abnormality arisen from the trouble light of the
pressurizing device, the test shall be immediately stopped and the reason shall be
found out.
6 试验时，压力试验人员应尽量避免站在储罐接管出口方向。

During the
test, the pressure test personnel shall try to avoid standing at the direction of the tank nozzle outlet.
7 各接管应用耐压大于试验压力的密封件密封，各连接件部位的紧固螺栓
应按规定的材料规格、数量装备齐全。

严禁在试验过程中，带压紧固螺栓及其他紧固件。

Every nozzle shall be sealed by the sealing element whose pressure
resistance is more than the test pressure, the fastening bolt on every coupling
position shall be completely provided according to specified specification and
quantity of materials. During the test, do not fasten bolts and other fasteners with
pressure.
8 试验用电必须有专职电工，非专职电工不得擅自接电。

The electricity used
for test must be operated by full-time electricians, and non-full-time electricians
shall not connect the power supply without authorization.
9 试验过程中，如发现有异常响声，停止试验，查明原因。

During the test,
in case of any abnormal noise, please stop the test and find out the reason.
10 试验时，各部位的紧固螺栓必须装配齐全。

During the test, fastening bolts
on every position shall be completely assembled.
11 压力试验时，不得带压进行任何修理和紧固工作。

During the pressure
test, do not execute any work of repair and fastening with pressure.
12 压力试验时，严禁人正对着法兰侧面站着。

During the pressure test, do
not stand right opposite to the side of the flange.
7.2.2 文明施工Civilized construction
1 凡参加施工人员必须熟知本工种安全操作规程，并严格遵守。

All construction staff should know well about safety operation regulations of their work and strictly abide by them.
2 进入施工现场戴好安全帽，高空作业系好安全带。

Wear safety helmets in case of entrance into the job site, and safety belts shall be appropriately worn at elevated work.
3 各施工机械必须专人看管，定期维修，保持施工机械处于良好状态。

All construction machinery must be attended by specially assigned personnel, and maintained regularly, so that the construction machinery keeps in good condition.
5 施工现场的材料、机具、工具放置应整齐，保持清洁Materials, machines and tools
on the job site shall be neatly placed and kept clean.
八人力计划VII. Planning for Labor Forces
九．施工机具Construction Machine and Tools
塞拉尼斯（南京）乙酰基中间体有限公司工业乙醇项目
Celanese China Fast Project
十．工作危险源分析评估及预防Work-related Hazard Analysis Evaluation and Prevention
1。