水压试验及冲洗程序(中英)

ProcedureforHydrostaticTestingandFlushingofPiping管线水压试验及冲洗程序编号Ref.No:NH-HDPE+PP-WPR-211Plant:PP+HDPEcontractor:TCMREV：BClient:CSPCSubcontractor:CP6CCPage1of10CONTENT目录Scope范围Reference参考文件PersonnelSafety人身安全GeneralRequirements一般要求Record记录Revision修订ProcedureforHydrostaticTestingandFlushingofPiping管线水压试验及冲洗程序编号Ref.No:NH-HDPE+PP-WPR-211Plant:PP+HDPEcontractor:TCMREV：BClient:CSPCSubcontractor:CP6CCPage1of10Scope范围ThisworkdetailsthemethodofhydrotestingfortheCSPCNanhaiPetrochemicalProjectHDPE/PPPipesabove/undergroundtobetested.本程序叙述了南海石化项目HDPE+PP装置管线系统进行水压试验及冲洗的一般要求。该试验程序适用于所有地上和地下管线的试验和冲洗。References参考文件NH-HDPE+PP-WPR-208PREFAB.&ERECTIONPROCEDUREFORPROCESSPIPING工艺管线 施工 文明施工目标施工进度表下载283施工进度表下载施工现场晴雨表下载施工日志模板免费下载 程序PR-8710-0000-0067-CSPC管道工程试压试漏PR-8130-0000-0007-CSPCFLUSHINGANDBLOWINGOFLINESANDEQUIPMENT管道和设备的冲洗与吹扫ASMEB31.3Processpipeline工艺管道PersonnelSafety人生安全PersonnelSafetyrefertothesection14ofPROCEDUREFORPROCESSPIPINGCONSTRUCTION-NH-HDPE+PP-WPR-208.人生安全要求见“工艺管线施工程序”，文件号为NH-HDPE+PP-WPR-208中第14节。GeneralRequirements一般要求Thisprocedureappliestoarangeofdifferenttypeoftestsfordifferentcombinationsofassembliesandpipe.本程序适用于对组件与管子的不同组合所进行的各种不同类型的水压试验及冲洗要求。NoticetoTCM通知TCMNoticeofinspectionshallbegiventoTCMpriortocleaning/gauging,filling,Hydrotestinganddewateringthepipe.在对管路进行清洗、水压试验之前，应将检验通知送达TCM工程师。ProcedureforHydrostaticTestingandFlushingofPiping管线水压试验及冲洗程序编号Ref.No:NH-HDPE+PP-WPR-211Plant:PP+HDPEcontractor:TCMREV：BClient:CSPCSubcontractor:CP6CCPage1of10Watersourcesandfilling水源与充水Mainlinepipesections(gatheringlines)willbefilledfromanapprovedwatersource.SamplesofwaterwillbeanalyzedandtheresultingreportwillbereviewedbyQCdepartment,priortofillingthepipe.Temporarypumpstation(s)willbeestablishedattherequiredlocation(s)andwilltypicallyconsistofone(1)centrifugalpumps(60mmNPSH)withacapacityof60m3/hrfittedwithinletbasketfilterandfootvalve(ifnecessary),andinterconnectingpipeworkandvalve.Cl＋contentofthewaterisnomorethan25ppmwhentestingthestainlesssteelwithsamplestakenforanalysis,fromthefillingpointforthetest-system.Thisrequiresthatspecialtanks,hoses,etc.arededicatedforhandlingthedeminwaterfortestingstainlesssteelpipe.Allsuchequipmentshallbewashedcleanpriortouseandthenflushedout,priortofillingaSSpipesystem.在不锈钢管系统冲水前，应将所有设备清洗干净后再对其进行彻底冲洗，然后再投入使用。管道水压试验及水冲洗用水，来自一处经过批准的水源，并应取水样进行分析，在冲水之前，分析记录由QC部门确认。在需要的位置建立临时泵站，这种泵站典型的构成形式包含有能力为60m3/小时,且装配有入口管式过滤器和吸管端逆止阀(如必要的话)的离心泵(60mmNPSH)、互连管路和控制阀门。当使用从测试系统冲水点中抽出的水样对不锈钢管道进行测试时，水中氯离子含量不得超过25ppm。不锈钢管的实验需要使用专用罐和软管等来装运DEMIN水管道清洗PipelineFlushing4.4.1管道清洗方式为水冲洗、空气吹扫、蒸汽吹扫。Ingeneral,pipingshallbewashedbyflushing,airblowingorsteamblowing.DNWIOOmm的管道及仪表风管、氮气管、燃料气系统管线采用压缩空气吹扫。PipesofDNW100mmandinstrumentairtubes,nitrogenpipesandfuelgassystempipelinesshallbeblownwithdriedcompressedair.蒸汽介质管线采用蒸汽吹扫。Steammediapipelinesshallbeblownwithsteam.DN>100mm的其它介质管道采用水冲洗。ProcedureforHydrostaticTestingandFlushingofPiping管线水压试验及冲洗程序编号Ref.No:NH-HDPE+PP-WPR-211Plant:PP+HDPEcontractor:TCMREV：BClient:CSPCSubcontractor:CP6CCPage1of10OthermediapipelinesofDN>100mmshallbeflushedwithwater.Certainprocesssystemsmayrequirealternativeflushingmethods,duetoprocessorcleanlinessrequirements.由于工艺和清洁度要求，一些工艺系统需要可选择的冲洗方法。Priortocleaningandpurgingpipingsystem,thefollowingconditionsshallbemet.系统清洗和吹扫前应具备以下条件Makeupthepurgingandcleaningflowdiagramforpipingsystem.Thepurging,cleaningdirectionandsequenceshallbeclearlymarkedontheflowdiagram,aswellaslocationandcapacityofwaterstoragetanks,pumps,isolationpoints,temporaryspools,valves,hoses,etc.Examplecalculationsshallbeattachedtodemonstratethatminimumrequiredflushingvelocitieswillbeachievedinallsectionsoftheplannedflushingsystem.编制系统冲洗和吹扫流程图，图中需要标出吹洗方向和顺序，储水罐、泵、隔绝点、临时管、阀和软管等的位置和容量。应附上计算书，以说明原 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冲水系统中的所有环节都能达到水速的最低要求。准备系统冲洗和吹扫所需的记录资料。Getreadyallrecordinginformationrequiredforsystemflushingandblowing.Allorifices,venturitubes,nozzles,strainers,adjustablevalves,flowmetershallberemovedfrompipingsystemandreplacedwithnipplejointinganddetailrecordinflushingdocument.管道系统上的孔板、文丘里管、喷嘴、过滤网、调节阀和流量计等应拆除换上短管并做好记录。Allpipesorequipmentwhicharenotincludedintestingsystemforcleaningandpurgingshallbesegregatedfromsystem.不参与吹洗的管道和设备已与系统隔离。Eachflushingsystemshallbeanalyzedforhydraulicforceduringflushingandsufficienttemporarysupportsandrestraintsshallbeinstalledtopreventpipemovementandtoprotectworkers,equipmentandtheenvironment.在冲洗期间，每个冲洗系统都应分析其水压力。应安装足够的临时支撑和障碍ProcedureforHydrostaticTestingandFlushingofPiping管线水压试验及冲洗程序编号Ref.No:NH-HDPE+PP-WPR-211Plant:PP+HDPEcontractor:TCMREV：BClient:CSPCSubcontractor:CP6CCPage1of10物来防止管道移位并保护工人，设备和环境不受损害。4.4.3吹洗顺序sequenceofflushingandblowing按先主管，后支管，最后疏排放管。Mainlinesfirstfollowedbybranchesandfinallydischargelines.水冲洗waterflushingThepurgingbywatershallbedonecontinuously,theminimumflowrateshallbenolessthan1.5m/s,thetemporarydischargepipeshallberoutedtotheditchordrainswell.Forlargervolumesystems,considercapturingthewaterortransferringittootherflushingsystems.AccordingtoGB50235,cleaningresultcanbeacceptedattheconditionthatthewaterqualityatboththeinletandoutletofpipingarethesame.水冲洗应连续进行，水的流速不小于1.5米/秒，临时冲洗排放管应通向排水井或沟。对大容量系统的冲洗水，应考虑重复利用或将其转换到其它冲洗系统。按照GB50235，冲洗则以出口的水色和透明度与入口一致为合格。空气吹扫airblowing吹扫压力不得超过管道的 设计 领导形象设计圆作业设计ao工艺污水处理厂设计附属工程施工组织设计清扫机器人结构设计 压力，流速不宜小于20m/s。theblowingpressureshallnotbehigherthanthedesignpressureandthevelocityofflowshallbelessthan20m/s.质量检验：管道系统重复吹扫后，当目测排气无烟尘时，在排气口设点贴白布或涂白漆的木制靶检验，然后再次吹扫。对于 标准 excel标准偏差excel标准偏差函数exl标准差函数国标检验抽样标准表免费下载红头文件格式标准下载 工艺管道，假如5min后靶板上无铁锈、尘土、水分及其它杂物为合格，除非TCM或BSC有其它要求。Qualityinspection:Afterrepeatedblowingofapipe-system,whennodustandfumeareseenduringblowing,putatargetwithapieceofwhiteclothorpaintedwithwhitepaintatexhaustoutlet.Thenrepeatair-blowing,Forstandardprocesspiping,after5minutes,ifthewhitetargetshowsnorust,dust,moistureandotherimpurities,thentheair-blowingwillbeconsideredacceptable,unlessadvisedotherwisebyTCMorBSC.蒸汽吹扫steamblowinga)从总汽阀开始，沿蒸汽流向逐个拆开集水管下面的法兰，分段进行。ProcedureforHydrostaticTestingandFlushingofPiping管线水压试验及冲洗程序编号Ref.No:NH-HDPE+PP-WPR-211Plant:PP+HDPEcontractor:TCMREV：BClient:CSPCSubcontractor:CP6CCPage1of10Steamblowingshallbecarriedoutsectionbysectionbyremovingtheflangesunderthecollectingpipealongtheflowdirectionofsteamstartingfromthemastervalve.b)吹洗时，应先向管内注入少量蒸汽，使集管慢慢变热，关闭蒸汽供给，通过开启集管阀门吹扫管线。Whenblowing,asmallamountofsteamshallbeinjectedintothepipetograduallywarmuptheheader,andthenstopsupplyingsteam,blowingthepipelinebyopeningtheheadervalve.吹洗集管采用总汽阀控制流量，吹洗支管采用管路中各分支处控制阀门。Theflowiscontrolledbythemainvalvewhenblowingtheheaderandbybranchcontrolvalveswhenblowingthebranches.吹洗压力尽量保持在管道设计工作压力的75%左右，吹洗流量为管道设计流量的40〜60%。Theblowingpressureshallbekeptatascloseto75%ofthedesignworkingpressureaspossible.吹洗次数不低于两次，间断进行，直到管道干净。Blowingactivityshallbeperformedatleasttwotimesinanintermittentwayuntilthecleannessofthepipelineisachieved.质量检验：以置于排汽口处的靶板检查，靶板上冲击斑痕的粒度及点数要求如下表。Qualityinspection:thepipelineisinspectedbysettingaboardatexhaustoutlet.Theparticlesizeandnumberofpointsofimpactmarksshallbeseenasfollows.吹扫质量标准Blowingqualitystandard项目Item质量标准Qualitystandard靶板上痕迹大小Sizeofmarkontargetbelow①0.6痕深DepthV0.5mm粒数Number1piece/cm2时间Time15min(两次均合格)BotharequalifiedProcedureforHydrostaticTestingandFlushingofPiping管线水压试验及冲洗程序编号Ref.No:NH-HDPE+PP-WPR-211Plant:PP+HDPEcontractor:TCMREV：BClient:CSPCSubcontractor:CP6CCPage1of10TheTCMrepresentativeandoperationspersonnelattheiroptionshallbepresentduringdrying,andcleaningofpipes.Therecordsofcleaningandpurgingshallbemadeafterpurging.管道清洗时，TCM有关人员应参与，合格后填写管道系统清洗记录。4.5Pressuretesting水压力试验4.5.1Priortotestingpipingsystem,thefollowingitemsshallbecomplete管道系统试验前应具备以下条件：Constructionforpipingsystemhasbeencompletedasperdrawings,supportsandhangershavebeenerectedandthoroughlycheckedasperdrawing.管道系统按图纸施工完毕，支、吊架安装完毕，并按图纸核对完毕。Testsystemhasbeenwalked-downtoconfirmthatallhigh-pointshaveventsandlow-pointshavedrain-connectionsinstalled.MissingventsanddrainsshallbeinstalledandassociatedNDE,priortoproceedingwithtesting.分解测试系统以确保所有高点装有通风孔，低点装有排水口。在试压之前应完成所缺的通风孔和排水口的安装并对其进行无损实验。Non-destructivetestshavebeencompleted,nopaintcanbecoatedatweldingseamsandotherpositionwhicharegoingtobetested.无损检测和管道冲洗完毕，焊缝及其它应检部位，不应涂漆。Allburiedpipe'scoordinates,elevation,grade,pipebasisandpaddinghavebeenverified,documentedandaccepted,alltemporaryreinforcementmeasureshavebeenverifiedtoensurethattheyaretightlysecured.埋地管道的坐标、标高、坡度及管基、垫层等经复查合格。试验用的临时加固 措施 《全国民用建筑工程设计技术措施》规划•建筑•景观全国民用建筑工程设计技术措施》规划•建筑•景观软件质量保证措施下载工地伤害及预防措施下载关于贯彻落实的具体措施 经检查确认安全可靠。AllQCformsshallbedocumentedaccordingtoQUALITYPLAN&PROCEDUREandacceptedbyQCdepartmentandotherrelateddivisions.按照质量计划和程序应填写的各种QC表格齐全，并经QC部及有关部门认可。Testgaugeshavebeencalibrated,theaccuracyshallbenolessthan+/-1%andthemaximumscalerangeshallbe1.5-3.0timesofthemaximumtestpressure.AtleasttwoProcedureforHydrostaticTestingandFlushingofPiping管线水压试验及冲洗程序编号Ref.No:NH-HDPE+PP-WPR-211Plant:PP+HDPEcontractor:TCMREV：BClient:CSPCSubcontractor:CP6CCPage1of10gaugesareneededinonesystem,onelocatedatthehighestpointandoneatthelowestpoint.试验用的压力表已经校验，精度不低于+/-1%，表的满刻度值为最大压力的1.5-3.0倍，一个系统中至少需要2块压力表，分别安装在最高点和最低点上。Allmandatorypunchlistinspectionshavebeenperformedbyallpartiesandallidentifiedpre-testitemshavebeencompletedandthepunchlistssigned-offbytheauthorizedparties.各方都已进行必须的整改检查,所有确认的预测试项都已完成并由有关方签字认可。Thelocationofgaugeandblindboardshallbemarkedinthetestsystemflowdiagram.Testpackageshallbeprepared.编制压力试验包。试验流程图中要求标出压力表位置，需要加盲板的部位。Thetestapplicationshallbeverified,approvedandacceptedbyrelateddepartment.试压申请单经有关部门审批、认可。Alltheequipment,instrumentsandpipefittingswhicharenotincludedinthetestsystemshallbesegregatedorremovedfromthepipe-systembeforetesting,theblindinglocationshallbeclearlymarkedandrecorded.试压前应将不参与试压的系统、设备、仪表以及管道附件等与管道系统隔离开来加盲板的部位应有明显标记和记录。Checktheprocessflowandopentherelativevalvestotheirhalf-openpositionsbeforepressure-test.Incaseflowdirectionoftestingmediumisreversedtoflowdirectionofnon-returnvalve,thevalve'scorewhichhasbeentakenoutshallbelabeled,andrecordsmade,andreinstalledaftertestingandcleaning,usingnewgasketssuppliedbythevender.试压前检查工艺流程，打开有关阀门至半开位置，试压介质流向如果与止回阀流向相反，则将其阀心取出，取出的阀心应贴上标记并作记录，试压和清洁后再用供货商提供的新垫片重新安装。4.5.4试验压力ProcedureforHydrostaticTestingandFlushingofPiping管线水压试验及冲洗程序编号Ref.No:NH-HDPE+PP-WPR-211Plant:PP+HDPEcontractor:TCMREV：BClient:CSPCSubcontractor:CP6CCPage1of10a)Hydrostatictestpressureshallbeaslistedonthepipingschedules,butingeneralwillbe1.5timesofdesignpressure.水压试验压力应符合管道表的要求，但通常为设计压力的1.5倍。b)Ifthedesigntemperatureishigherthantesttemperature,theminimumtestingpressureofthepipewillbeincreasedbyatemperaturecorrectionfactor,inaccordancewiththerequirementofASME.B31.3.对于设计温度高于试验温度的管道，最小的试验压力将按ASME.B31.3要求增加一个温度修正因素。当管道与容器作为一个系统进行水压试验，试验压力按设计或规范要求。Whenpipelinesandvesselsarehydrotestedasonesystem,testpressureshallbeinaccordancewithdesignorspecificationrequirement.4.5.5试验要求Testingrequirea)Testingwatershallflowintothepipingsystemfromthelowestdrain,allairinthesystemmustbepurgedoutfromthehighestvent,onegaugemustbeplacedatthehighestposition.水压试验系统充水时尽量从管道底部充入，在管道系统最高点将系统内部的空气排尽，最高点必须装压力表。b)Hydrostatictestpressureshallslowlyrise.Afterthepressurereachesthetestpressure,itshallbeheldforonehour.Iftherearenopressuredrop,andnodeformationtopipebyvisualview,thenthepressureshallbereducedtothedesignpressuretocheckthepipingthoroughly,includebutnotlimitedtotheweldingseam,valve,flange.Thetestcanbeacceptediftherearenoleaksandpressure-dropsaftercheckofallpipingsystem.Allleaksshallberepairediftheyarefound.Priortorepair,thepressureinthepipingshallbedischargedfromsystem;repaircarryingpressureisnotpermitted.缓慢升压，达到试验压力后，停压10分钟，如无压降、目测管道无变形，然后压力降至设计压力，对管道系统全面检查，包括但不限于焊缝、阀门、法兰口，经全面检查管道系统无泄漏、无压降为合格。如果发现泄漏，应该泄压处理，不得带压操作。ProcedureforHydrostaticTestingandFlushingofPiping管线水压试验及冲洗程序编号Ref.No:NH-HDPE+PP-WPR-211Plant:PP+HDPEcontractor:TCMREV：BClient:CSPCSubcontractor:CP6CCPage1of104.6Dewatering放水Dewateringofthepipelinetestsectionsshallbeplannedandequipmentprovidedtodirectthemajorityofwaterintoeithertemporaryorpermanentdrainsystems.Hosesandpumpswillbeusedwhererequired.Releaseofsignificantamountsoftest/flushingwaterontoflatgroundorpavingshallnotbeallowed,unlessprovisionforcontainmentordrainageisprovided.Careshallbetakensothatwaterisdisposedofwithoutcausingerosionorflooding.应计划实验管段的放水工作，并提供设备将大部分水引入临时或永久排水系统，必要时还应使用软管和泵。不允许将大量实验/冲洗水直接排放至平地或路面上，除非有排污池。应注意对排放水的处理，使之不会造成过度冲刷或泛滥。Afterthepipelinepasseshydrotest,allairbleedingvalvesshallbeopenedfirstwhendischargingwater,andthenopenthedischargevalvegraduallytodischargethewater.水压试验合格后，放排水时应首先打开所有的排气阀，然后逐渐地打开排放阀，排放试验水。记录Recording5.1管道水压试验记录SH-3503-J407Recordsofpipelinehydrotest.5.2管道冲洗与吹扫记录SH3503-J409Recordsofpipelineflushingandblowing.修订Revision若发现此程序不能充分保证工程项目的完成，遇到新的施工情况或经过PMC要求将对该程序进行修订。ThisprocedureshallberevisedifitisfoundtobeinadequateforthecompletionofthepurposedWorksornewconstructionconditionsareencounteredorasrequestedbyTCM.