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1、压缩空气系统管道试压及吹扫方案Compressedairsystempipelinepressuretestandpurge目录一、 编制说明COmPilatiOninstructions-1-二、 工程概况PrOjeCtOverview-1-21工程简介PrOjeCtIntroduction-1-2. 2管道试验分为三个阶段：Thepipelinetestisdividedintothreestages：-2-3. 3试压的重点部位：Keypartsofpressuretest:-2-三、 编制依据COinPilationbasis-3-3.1 相关标准Relatedstandards一3一
2、32相关图纸Relateddrawings-3-四、 施工计划COnStrUCtiOnplan-4-41人员配置Staffing-4-42材料准备MateriaIpreparation-4-4 .3试压方案Pressuretestplan-5-5 .4管道吹扫Pipepurge-11-五、 质量保证措施QUalityassurancemeasures-15一5.1 管道试压质量保证措施QUalityAssuranceMeasuresforPipelinePressureTest一15一5.2管道吹扫质量保证措施PiPeIinepurgequalityassurancemeasures.-17-
3、六、施工安全保证措施Constructionsafetyassurancemeasures-19-6.1安全管理方针和目标Safetymanagementpolicyandobjectives-19-6.2安全保证体系SecurityAssuranceSystem-20-6.3安全技术保证措施Safetechnicalassurancemeasures-20-七、危险源辩识与风险评价结果一览表Listofhazardidentificationandriskassessmentresults-28-一、编制说明Compilationinstructions本方案适用于孟加拉KHULNA2003
4、00MW联合循环(双燃料)电站项目空压机房区域，燃机房及余热锅炉区域，汽机房区域及化学厂区压缩空气管道试压、吹扫工作。ThisschemeissuitableforpressuretestingandpurgingofcompressedairpipelinesinBangladeshKHULNA200300MWcombinedcycle(dualfuel)powerstationproject,gasturbineroomandwasteheatboilerarea,steamengineroomareaandchemicalplantarea.二、工程概况ProjectOverview2.
5、1工程简介ProjectIntroduction本工程压缩空气系统主要分为仪用压缩空气和厂用压缩空气，区域分为空压机房、燃机房及余热锅炉、汽机房和化学厂区四个区域。系统试压及吹扫介质为空气，使用空压机A直接制气。管道技术参数详见下表：Thecompressedairsystemofthisprojectismainlydividedintoinstrumentcompressedairandfactorycompressedair.Theareasaredividedintofourareas:aircompressorroom,gasturbineroomandwasteheatboiler
6、,steamengineroomandchemicalplantarea.Thesystempressuretestandpurgemediumisair,andaircompressorAisusedtodirectlyproduceair.Thetechnicalparametersofthepipelineareshowninthefollowingtable:管道技术参数表Pipelinetechnicalparametertable表1Table1图号FigureNo.名称Name最高工作压力Maximumworkingpressure(MPa)设计压力designpressure(
7、MPa)试验压力testpressure(MPa)管道总长Totallengthofpipeline(m)备注Remark33-F0915IS-Jll03空压机房压缩空气管道Compressedairpipelineinaircompressorroom1.511134114*4,99m140*3.5,13m76*3.5,22m33-F0915IS-Jll04燃机及余热锅炉区域压缩空气管道1.51169089*4,125m76*3.5,170m60*3,195m32*3,200mCompressedairpipelinesforgasturbineandwasteheatboilerarea3
8、3-F09151S-J1105汽机房压缩空气管道Compressedairpipelineinturbineroom1.51144576*3.5,180m60*3,225m32*3,40m33-F09151S-J1106厂区压缩空气管遒Compressedairpipelineinthefactory1.511571140*4.5,95m114*4,95m89*4,290m76*3.5,40m60*3,45m32*3,6m总计total18402.2管道试验分为三个阶段：Thepipelinetestisdividedintothreestages:第一阶段：空压机启动，系统升压第二阶段：系统
9、压力到达试验值，系统稳压第三阶段：压力稳定后，系统捡查漏点第四阶段：系统分区域吹扫Thefirststage:theaircompressorstarts,thesystemisboostedThesecondstage:thesystempressurereachesthetestvalue,andthesystemstabilizesThethirdstage:Afterthepressurestabilizes,thesystemchecksforleaksThefourthstage:thesystemsub-regionalpurge2.3试压的重点部位：Keypartsofpres
10、suretest:易燃、易爆、有毒、有腐蚀等介质系统。如：燃油区域、化学水区域、制氢站区域。Inflammable,explosive,toxic,corrosiveandothermediasystems.Suchas:fuelarea,chemicalwaterarea,hydrogenproductionstationarea.三、编制依据Compilationbasis3.1 相关标准Relatedstandards3. 1.1GB50235-1997工业金属管道施工及验收规范；4. L2GB/压力管道规范工业管道第4部分：制作与安装。5. 1.1GB502351997zzCodefo
11、rConstructionandAcceptanceofIndustrialMetalPipelines”;6. 1.2GB/zzSpecificationforPressurePiping,IndustrialPipingPart4:ProductionandInstallation”.3.2 相关图纸Relateddrawings3.2.1浙江省电力设计院有限公司图纸空压机房压缩空气管道33-F09151S-J11033.2.2浙江省电力设计院有限公司图纸燃机及余热锅炉区域压缩空气管道33-F09151S-J11043.2.3浙江省电力设计院有限公司图纸汽机房压缩空气管道33-F09151
12、S-J11053. 3.4浙江省电力设计院有限公司图纸厂区压缩空气管道33-F09151S-J1106)4. 2.1DrawingsofZhejiangElectricPowerDesignInstituteCo.,Ltd.zzCompressedAirPiping33-F09151S-J1103forAirCompressorROonr5. 2.2DrawingofZhejiangElectricPowerDesignInstituteCo.,Ltd.zzGasTurbineandWasteHeatBoilerAreaCompressedAirPiping33-F09151S-Jl104z,
13、6. 2.3DrawingofZhejiangElectricPowerDesignInstituteCo.,Ltd.CompressedAirPipeline33-F0915IS-Jl105inTurbineRoom”7. 3.4DrawingofZhejiangElectricPowerDesignInstituteCo.,Ltd.,zPlantCompressedAirPipeline33-F0915IS-Jl106四、施工计划COnStrUCtiOnPIan7.1 人员配置Staffing7.1.1 劳动力计划Workforceplan序号Serialnumber工种Typeofwor
14、k数量quantity备注Remark1管工Plumber6people2架子工Shelfworker6people3氢弧焊工Argonarcwelder1people4电焊工Ordinarywelder1people5工长Foreman2人/people6工程师engineer1AZpeople7安全员Securityofficer1people8质量员Qualitystaff1people9总计total19people7.2 材料准备Materialpreparation7.2.1 材料计划Materialplan序号Serialnumber材料名称Materialname规格Speci
15、fication数量Quantity备注Remarks1架子钢管SheIfsteelpipe48,L=6m200root2跳板Springboard4038#铁丝8#ironwire50kg4洗衣粉WashingpowderIOkg5小桶smallbuckets5L10个6毛刷brushes25mm20把7木板(靶板XVoodenboard(target1220060010005块board)8白布或白色塑料布Whiteclothorwhiteplasticcloth5m29安全带seatbelts20副10防坠绳Anti-droppingrope200m11防坠器Anti-droppingd
16、evice20副12扳手wrenches20035020把13手锤HandhammerIkg5把14木板woodboard10008005块吹扫口遮挡用forblockingtheblowoutport15石棉橡胶板Asbestosrubbersheet3mm10m216剪刀Scissors2把17对讲机Intercom4只18压力表Pressuregauge0L6MPa,CL1.64块19喷壶wateringcan2.5L4个7.2.2 介质需求计划MediaRequirementsPlanning压缩空气，压力WIMPaCompressedair,pressureIMpa7.3 试压方案P
17、ressuretestplan7.3.1 试压技术要求Pressuretesttechnicalrequirementsa试压介质：压缩空气。b试验压力：1MPac鉴定标准：系统压力达到试验压力后稳压IOmin,将系统压力降低到设计压力，用发泡剂检查泄漏，无泄漏为合格。aPressuretestmedium:compressedair.bTestpressure:1MPacAppraisalstandard:Afterthesystempressurereachesthetestpressure,stabilizeitfor10minutes,reducethesystempressureto
18、thedesignpressure,andchecktheleakagewithafoamingagent.Noleakageisconsideredqualified.7.3.2 试压工艺流程Pressuretestprocess安全技术交底一物资准备一安装试压用临时气源管和压力表一安装末端临时阀一关闭主干管末端临时阀f开启空压机临时冷却水水泵一开启空压机冷却水入口阀门f开启厂用及仪用储气罐入口主阀门一关闭厂用及仪用储气罐出口主阀门一开启空压机A缓慢充压一检查泄漏一系统压力达到0.3MPa稳压3分钟一检查泄漏f压力每升高0.3MPa稳压3分钟f检查泄漏一压力达到IMPa稳压10分钟一检查厂用
19、及仪用储气储气罐泄漏（无泄漏为合格）f厂用及仪用储气储气罐全部合格后缓慢开启罐出口主阀门一系统管道压力达到03MPa稳压3分钟一检查泄漏一压力每升高0.3MPa稳压3分钟一检查泄漏一压力达到IMPa稳压10分钟f检查系统管道泄漏（无泄漏为合格）情况一全部管道合格后试压结束。Safetytechnicalclarification-*materialpreparation-*installationoftemporaryairsupplypipeandpressuregaugeforpressuretest-*installationoftemporaryendvalve-*closetempo
20、raryvalveattheendofmainpipe-*openaircompressortemporarycoolingwaterPUlnPfOPenaircompressorcoolingwaterinletvalve_*openMaininletvalveofgasstoragetankforfactoryandinstrument-*Closemainoutletvalveofgasstoragetankforfactoryandinstrument-TurnonaircompressorAtoslowlychargepressurefCheckforleakage-Systempr
21、essurereaches0.3MPaandstabilizesfor3minutes-*Checkforleakage-*Whenthepressurerisesby0.3MPa,stabilizethepressurefor3minutesfcheckleakagefwhenthepressurereaches1MPaandstabilizethepressurefor10minutes-checktheleakageofthefactoryandinstrumentgasstoragetanks（noleakageisqualified）-thefactoryandinstrumentg
22、asstorageAfterthetanksareallqualified,slowlyopenthemainvalveofthetankoutlet-*thesystempipelinepressurereaches0.3MPaandstabilizesfor3minutescheckforleakagefevery0.3MPaincreaseinpressureandstabilizesfor3minutes-*checkforleakage-thepressurereaches1MPaandstabilizesfor10minutesfcheckthesystempipelineLeak
23、age（noleakageisqualified）fThepressuretestendsafterallthepipelinesarequalified.7.3.3 试压前的准备Preparationbeforepressuretest4.3.3.1安全技术交底。由试压、吹扫技术负责人向参加管道试压、吹扫的全体管理人员和工人进行安全技术交底；并做好记录。43.32物资准备。作业队按照批准的方案准备所需物资。4. 3.3.3安装临时压力表。将不参加试压和吹扫的设备与管路隔断，将正式压力表、安全阀拆下，用临时管连通，安装试压用压力表。临时设施设置方案：（1）气源设置：本工程直接使用空压机A制造压
24、缩空气冲入压缩空气储气罐。临时压力表设置：在燃机房A列1线、B列2线安装4块临时压力表（Tl.6MPa,CL1.6（编号临1临2、临3临4）o在余热锅炉区域C列7线安装2块临时压力表0T.6MPa,CL1.6（编号临5临6）O在汽机房区域G列4线、B列1线安装4块临时压力表（Tl.6MPa,CL1.6（编号临7临8、临9临10）o在化学水区域PA-K列PA-I线安装2块压力表（TL6MPa,CL1.6（编号临11临12）8. 3.3.4试压前联合检查。管道、阀门、管道支架全部安装完，报验完。焊缝无损检验合格，报验完。试压用临时气源管道、连通管、临时阀门安装完。4. 3.3.1Securityt
25、echnicalclarification.Thepersoninchargeofthepressuretestandpurgetechnologyshallclarifythesafetytechnologytoallthemanagersandworkersparticipatinginthepressuretestandpurgeofthepipeline;andmakearecord.5. 3.3.2Materialpreparation.Theoperationteampreparestherequiredmaterialsinaccordancewiththeapprovedpla
26、n.6. 3.3.3Installtemporarypressuregauges.Separatetheequipmentthatdoesnotparticipateinpressuretestandpurgingfromthepipeline,removetheofficialpressuregaugeandsafetyvalve,connectwithatemporarypipe,andinstallapressuregaugeforpressuretest.Temporaryfacilitysettingplan:(1) Airsourcesetting:Thisprojectdirec
27、tlyusesaircompressorAtoproducecompressedairtoflushintothecompressedairstoragetank.(2) Temporarypressuregaugesetting:Install4temporarypressuregauges0l.6MPa,CL1.6(No.1L2,Lin3L4)inthefirstlineoflineAandline2oflineBofthegasturbineroom.Install2temporarypressuregauges(TI.6MPa,CL1.6(No.5L6)inline7ofcolumnC
28、inthewasteheatboilerarea.Install4temporarypressuregauges01.6MPa,CL1.6(No.7L8,Lin9、Llo)inthe4thlineofGcolumnand1stlineofBcolumninthesteamengineroomarea.Installtwopressuregauges01.6MPa,CL1.6(No.1P12)inthePA-IlineofPA-Kcolumninthechemicalwaterarea4. 3.3.4Jointinspectionbeforepressuretest.(1) Theinstall
29、ationofpipes,valves,andpipebracketsiscomplete,andtheinspectioniscompleted.(2) Thenon-destructiveinspectionoftheweldisqualified,andtheinspectioniscompleted.(3) Temporarygassupplypipes,connectingpipesandtemporaryvalvesforpressuretesthavebeeninstalled.4.3.4试压操作Pressuretestoperation4.3.4.1投入空压机A冷却水启动临时冷
30、却水泵，并检查临时冷却水管路及临时滤网是否有漏水情况，保证空压机冷却水出口正常出水。4.3.4.2设置压缩空气储气罐管道阀门1 .打开缓冲储气罐出入口主阀门2 .打开空压机A压缩空气出口阀门3 .打开厂用压缩空气储气罐入口阀门并关闭出口主阀门4 .打开仪用压缩空气储气罐入口阀门并关闭出口主阀门4.3.4.3启动空压机A检查空压机接地及临时电缆通电情况，检查无误后启动空压机，检查空压机是否运行正常无异响。4. 3.4.4储气罐试压1 .当空压机启动后给系统缓慢充压至系统压力达到O.3MPa时稳压3分钟2 .稳压过程中使用清洁剂稀释液喷洒到各接口处检查空压机房室内管道及储气罐有无泄露情况，有泄漏及
31、时处理，无泄漏继续升压3 .储气罐压力每上升0.3MPa,稳压3分钟并重复检漏工作，直至储气罐压力升至试验压力IMPa4 .当储气罐压力达到试验压力IMPa时，稳压10分钟5 .当空压机房管道及储气罐无泄露情况时，储气罐检漏工作结束，方可进行下一步。4. 3.4.5压缩空气系统管道试压L储气罐试压结束后，缓慢开启仪用储气罐出口主阀门2 .缓慢开启厂用储气罐出口主阀门3 .打开临时压力表（临临12）阀门，并时刻关注压力表数值4 .各区域管道每上升0.3MPa,稳压5分钟并进行检漏工作，直至管道压力升至试验压力IMPa5 .当管道压力达到试验压力IMPa时，稳压10分钟6 .当系统管道全部检查无泄
32、露情况，试验合格7 .3.4.6试压时安全注意事项试压区域必须设置禁区围栏，悬挂禁区标志牌，并派人看守；试压期间重点部位都要安排人员监护，作业未结束不得擅自离岗。管道沿线应有人行走台和安全绳；安装、拆卸临时管道、阀门、检查泄漏等高处作业的人员应佩带双钩双挂的安全带；并且至少2人一组，禁止单独1人作业；（4）试压用的压力表必须是在合格有效期内，一处必须安装2块；管道开始充压后管道上禁止一切安装和拆除，管道上压后禁止敲击管道；（6）管道上压后发现泄漏不准擅自处理，不准带压处理。必须报告指挥，由指挥决定如何处置。接到指挥通知并确认卸压后方可处理。4.3.4.1Putinthecoolingwater
33、ofaircompressorAStartthetemporarycoolingwaterpump,andcheckwhetherthetemporarycoolingwaterpipelineandthetemporaryfilterareleakingtoensurethatthecoolingwateroutletoftheaircompressorisnormallydischarged.4.3.4.2Setcompressedairstoragetankpipelinevalve1. Openthemainvalveattheinletandoutletofthebuffergass
34、toragetank2. OpenthecompressedairoutletvalveofaircompressorA3. Opentheinletvalveofthefactorycompressedairstoragetankandclosethemainoutletvalve4. Opentheinletvalveofthecompressedairtankfortheinstrumentandclosethemainoutletvalve5. 3.4.3StartaircompressorACheckthegroundingoftheaircompressorandtheenergi
35、zationofthetemporarycables.Aftertheinspectioniscorrect,starttheaircompressor,andcheckwhethertheaircompressorisoperatingnormallyandwithoutabnormalnoise.6. 3.4.4Gasstoragetankpressuretest1. Aftertheaircompressorisstarted,slowlychargethesystemuntilthesystempressurereaches0.3MPaandstabilizethepressurefo
36、r3minutes2. Intheprocessofvoltagestabilization,spraythedetergentdiluenttoeachinterfacetocheckwhetherthereisanyleakageintheindoorpipelineandgasstoragetankoftheaircompressorroom.Ifthereisaleakage,dealwithitintime,andifthereisnoleakage,continuetoincreasethepressure.3. Everytimethepressureofthegasstorag
37、etankrisesby0.3MPa,stabilizethepressurefor3minutesandrepeattheleakdetectionworkuntilthepressureofthegasstoragetankrisestothetestpressureof1MPa4. WhenthepressureofthegasstoragetankreachesthetestpressureofIMPa,stabilizethepressurefor10minutes5. Whenthereisnoleakageintheaircompressorroompipelineandgass
38、toragetank,theleakdetectionofthegasstoragetankiscompletedbeforeproceedingtothenextstep.4. 3.4.5Compressedairsystempipelinepressuretest1. Afterthepressuretestofthegasstoragetank,slowlyopenthemainvalveattheoutletofthegasstoragetankfortheinstrument2. Slowlyopenthemainvalveattheoutletoftheplantgasstorag
39、etank3. Openthevalveofthetemporarypressuregauge(LinPLin12),andalwayspayattentiontothevalueofthepressuregauge4. Everytimethepipelineineacharearisesby0.3MPa,stabilizethepressurefor5minutesandperformleakdetectionworkuntilthepipelinepressurerisestothetestpressureofIMPa5. Whenthepipelinepressurereachesth
40、etestpressureofIMPa,stabilizethepressurefor10minutes6. Whenthesystempipelinesareallcheckedforleakage,thetestisqualified4. 3.4.6Safetyprecautionsduringpressuretest(1) Forbiddenareafencesmustbesetupinthepressuretestarea,andtherestrictedareasignsmustbehungandguarded.Duringthepressuretest,thekeypartsmus
41、tbemonitoredbypersonnel,andtheworkshallnotbeleftwithoutauthorization.(2) Thereshouldbeawalkingplatformandsafetyropealongthepipeline;(3) Personnelworkingatheightssuchasinstalling,disassemblingtemporarypipelines,valves,checkingforleaks,etc.shouldwearsafetybeltswithdoublehooksanddoublehooks;andatleasta
42、groupof2people,anditisforbiddentoworkbyonepersonalone;(4) Thepressuregaugeusedforpressuretestmustbewithinthequalifiedperiodofvalidity,andtwomustbeinstalledinoneplace;(5) Allinstallationanddismantlingisprohibitedonthepipelineafterthepipelineispressurized,anditisforbiddentoknockthepipelineafterthepipe
43、lineispressurized;(6) Afterthepipelineispressurized,iftheleakisfound,itisnotallowedtohandlewithoutauthorization,anditisnotallowedtohandleitunderpressure.Thecommandmustbereported,andthecommandwilldecidehowtodealwithit.Itcanbeprocessedonlyafterreceivingthecommandnoticeandconfirmingthatthepressureisrel
44、ieved.4.4管道吹扫Pipepurge管道试压工作结束并合格后，用厂内压缩空气对管道进行吹扫时其流速不低于20msoAfterthepipelinepressuretestiscompletedandqualified,theflowrateofthepipelineshallnotbelessthan20mswhenthepipelineispurgedwithcompressedairinthefactory.4.4.1 吹扫措施Purgemeasures由于管道管线较长，空管的吹扫用空压站的压缩空气进行吹扫，按照管道严密性试验中压力试验管路的配置原则在管道的末端加一个阀门，当压力达
45、到空压站出口压力后，快速打开阀门，将管道内的杂物吹出。Duetothelongpipelinelength,theemptypipeispurgedwithcompressedairfromtheaircompressorstation.Accordingtotheconfigurationprincipleofthepressuretestpipelineinthepipelinetightnesstest,addavalveattheendofthepipe,whenthepressurereachestheoutletoftheaircompressorstationAfterpress
46、ure,quicklyopenthevalvetoblowoutthedebrisinthepipeline.4.4.2 吹扫应具备的条件Conditionsforpurging1 .系统管道试压合格2 .不允许吹扫的设备及管道应与吹扫系统隔离3 .管道上不得有孔板、调节阀及重要的阀门、节流阀、安全阀、仪表等4 .吹扫管道安装好后，进行检查，管道必须牢固可靠，必要时对管道增加固定点，确保吹扫时管道无跳动5 .吹扫前各支阀必须关闭1. Qualifiedsystempipelinepressuretest2. Equipmentandpipesthatarenotallowedtobepurgedshouldbeisolatedfromthepurgingsystem3. Theremustbenoorificeplates,regulatingvalvesandimportantvalves,throttlevalves,safetyvalves,instruments,etc.onthepipeline4. Afterthepurgepipelineisinstalled,checkit.Thepipelinemustbefirmandreliable.Ifnecessary,addafixedpointto
