全密度工艺管线试压吹扫施工技术方案.doc

文件编号：DQLH-QMD-JSFA-18-2010大庆石化公司25万吨/年全密度聚乙烯装置（一）工艺管线试压吹扫施工技术方案中国石油天然气第一建设公司大庆项目经理部2011年4月14日版次：第A1版一般施工技术方案审批表 C2-02-2-1工程名称大庆石化公司25万吨/年全密度聚乙烯装置（一）编制人部 门审 批 意 见责 任 人总包（施 工） 单 位 审 批技术部门负责人：（公章） 年 月 日质量部门负责人：（公章） 年 月 日安全部门负责人：（公章） 年 月 日生产部门负责人：（公章） 年 月 日总工程师：（公章） 年 月 日监理 单位 审批监理工程师：年 月 日总监理工程师：（公章） 年 月 日建设 单位 审批项目组负责人： 年 月 日项目经理： （公章）年 月 日目录1 编制说明12 编制依据13 工程简介15 施工方案15.1试压系统的划分15.2特殊管道的处理285.3管道试压程序295.3试压准备295.4压力试验305.5管道吹扫及清洗316 质量管理及质量保证措施327 安全措施338施工机具及手段用料33附表一：试压盲板对照表35附表二：管道试压流程临时盲板位置表35附图一：管道试压系统流程图35附表一 施工进度计划附表二 管道安装工程单位工程划分附表三 工艺管线安装工程施工质量控制点及其内容1 编制说明25万吨/年全密度聚乙烯装置（一）布置在大庆石化公司乙烯厂厂区内。该装置的东侧为成品罐区；西侧为低压聚乙烯装置，南侧为厂区主干道；北侧为6万吨/年线性低密度聚乙烯装置。装置总占地面积22632m2。本工程建设单位为大庆石化公司，监理单位为大庆石化工程有限公司，设计单位为大庆石化工程有限公司，质量监督单位为大庆石化质量监督站，施工单位为中国石油天然气第一建设公司。本装置安装工程开工时间2010年5月5日，2012年5月30日中交。2 编制依据工业金属管道工程施工及验收规范GB50235-97现场设备、工业管道焊接工程施工及验收规范GB50236-98石油化工有毒、可燃介质管道工程施工及验收规范SH3501-2002工业金属管道工程质量检验评定标准GB50184-93大庆石化公司25万吨/年全密度聚乙烯装置（一）安装一标段施工组织设计大庆石化公司25万吨/年全密度聚乙烯装置（一）安装一标段质量计划3 工程简介本装置工艺管道安装部分我公司负责承担反应区、原料精制区、排放气回收区、造粒区、工艺主管廊、循环气压缩机区的工艺管线施工。本装置主要工艺介质有T2、T3、异戊烷、共聚单体、乙烯、1-丁烯、己烯、循环气、催化剂、调节剂、液态烃、脱盐水、冷却水、氮气、低压蒸汽、蒸汽凝液、装置空气、仪表空气等。管道涉及材质有20#、20G、20R、A333-GR.6、A671-CB60、0Cr18Ni9、TP304、TP316等。5 施工方案5.1试压系统的划分本工程管道试压原则上按照“分区域、分级别、分系统、分材质”进行。按照设计及规范要求，管道安装完毕，无损检验合格，对管道系统进行压力试验。针对本工程的特点，工艺管道的施工是按区域进行安装，由于各工艺区的施工进度、介质、工艺特点不同，本工程的工艺管道水压试验拟按照区域、管道级别、设计压力、管道介质、管道材质等多种因素，并根据流程图和管道设计压力对管道进行系统划分。确保先施工完的管道系统先进行试压的原则，进行流水式试压。因本工程采暖管线已经投用，经建设单位同意，现不再进行试压。试压系统主要划分为：原料精制区系统、排放气回收区系统、排放气压缩机区系统、反应区系统、造粒区系统和工艺管廊区系统等六大试压系统。每个试压系统按照管道试验压力、管道材质、管道介质进行划分试压包。每个试压系统的试压包划分如下：系统一：原料精制区系统精制区管道试压系统划分试压系统管线号设计压力（Mpa）试验压力（Mpa）系统试验压力（Mpa）A012-P-10B18-1E21/A4.0686.1026.2MPa2-P-10B04-1E21/A4.0686.1022-P-10B07-1E21/A4.0686.1023-P-10B11-1E21/A4.0686.1023-P-10B20-1E21/A4.0686.1022-P-10C01-6E57-(HC)-H2/A4.0686.1022-P-10C02-6E57-(HC)-H2/A4.0686.1022-V-10B02-1E21/A4.0686.1022-V-10B05-1E21/A4.0686.1022-V-10B16-1E21/A4.0686.1023/4-V-10B19-1E21/A4.0686.1023/4-V-10B20-1E21/A4.0686.102A022-P-10B10-1C15/A0.9311.39656.2MPa2-P-10C05-1E21/A4.0686.1022-P-10C09-1E21/A4.0686.1022-P-10C10-1E21/A4.0686.1022-P-10C11-1E21/A4.0686.1021-P-10C06-1E3-(PP)-P1/A3.8345.7512-P-10C07-6E57-(HC)-HR/A4.0686.1022-P-10C08-6E57-(HC)-HR/A4.0686.1026-P-10C03-6E57-(HC)-HR/A4.0686.1026-P-10C04-6E57-(HC)-HR/A4.0686.1022-V-10C05-6E57/A4.0686.102A036-N-10C01-1E3-(HC)-HR/A0.9311.39651.4MPa8-V-10C13-1C15-(PP)-P1/A0.20.32-V-10C04-6E57-(PP)-P5/A0.9311.39652-V-10C05-6E57-(PP)-P5/A0.9311.39653/4-V-10C02-6E57-(PP)-P5/A0.9311.39653/4-V-10C03-6E57-(PP)-P5/A0.9311.39656-V-10C08-6E57-(PP)-P5/A0.9311.39656-V-10C10-6E57-(PP)-P5/A0.9311.39658-V-10C01-6E57-(PP)-P5/A0.9311.39658-V-10C14-6E57-(PP)-P5/A0.9311.3965A043-V-14B12-1C15-(PP)-P5/A0.20.31.4MPa3-V-14B20-1C15-(PP)-P5/A0.9311.39652-V-14B05-1E21L/A0.9311.39651-V-14B04-6E57-(PP)-P5/A0.9311.39653/4-V-14B06-6E57-(PP)-P5/A0.9311.39653/4-V-14B08-6E57-(PP)-P5/A0.9311.39653-V-14B03-6E57-(PP)-P5/A0.9311.39653-V-14B07-6E57-(PP)-P5/A0.9311.3965A052-P-14B02-1E21/A4.0686.1026.2MPa2-P-14B06-1E21/A4.0686.10211/2-P-14B18-6E57-(HC)-HR/A4.0686.10211/2-P-14B19-6E57-(HC)-HR/A4.0686.1023-P-14B05-6E57-(ET)-E2/A4.0686.1023-P-14B12-6E57-(ET)-E2/A4.0686.102A063-LS-21B01-1C53D-(HC)-H3/A0.6550.98255.8MPa2-P-21B07-1E21-(HC)-H2/A3.8345.7511-P-21F06-1E21/A3.8345.7518-P-21F05-1E21/A3.8345.7512-P-21B08-1E21L/A3.8345.7512-P-21E02-1E21L/A3.8345.7518-P-21B04-1E21L/A3.8345.7518-P-21B03-1E21L/A3.8345.7518-P-21E11-1E21L/A3.8345.7518-P-21F02-1E3-(HC)-H6/A3.8345.7518-P-21F09-1E3-(HC)-H6/A3.8345.7512-P-21E08-1E3L-(HC)-HR/A3.8345.7513-P-21E12-1E3L-(PP)-P1/A3.8345.7513-P-21E13-1E3L-(PP)-P1/A3.8345.7513-P-21F07-1E3L-(HC)-H2/A3.8345.7513-P-21F10-1E3L-(HC)-H2/A3.8345.7518-P-21E03-1E3L-(HC)-HR/A3.8345.7518-P-21E04-1E3L-(PP)-P1/A3.8345.7518-P-21E05-1E3L-(HC)-HR/A3.8345.7518-P-21E06-1E3L-(PP)-P1/A3.8345.7518-P-21F01-1E3L-(HC)-H2/A3.8345.7518-P-21F08-1E3L-(HC)-H2/A3.8345.7518-P-21E07-1E3L/A3.8345.751A078-V-21D07-1C15-(PP)-P1/A0.10.151.4MPa3-V-21C03-1C15/A0.20.33-V-21C04-1C15/A0.20.38-V-21D02-1C2B-(PP)-P3/A0.0690.10356-V-21C01-1E3-(PP)-P3/A0.9311.39656-V-21C02-1E3-(PP)-P3/A0.9311.39656-V-21D03-1E3-(PP)-P3/A0.9311.39658-V-21D01-1E3-(PP)-P3/A0.9311.39658-V-21D04-1E3-(PP)-P3/A0.9311.3965A083-N-21G05-1E3-(HC)-HR/A0.9311.39651.4MPa3-N-21G12-1E3-(HC)-HR/A0.9311.39653-N-21G08-1E3-(ET)-E2/A0.9311.39654-N-21G07-1E3-(HC)-H6/A0.9311.39656-N-21G02-1E3-(HC)-H6/A0.9311.39656-N-21G03-1E3-(ET)-E2/A0.9311.39656-N-21C01-1E3-(HC)-H6/A0.9311.39656-N-21D02-1E3-(HC)-H6/A0.9311.39656-N-21D03-1E3-(HC)-H6/A0.9311.39656-N-21G11-1E3-(HC)-H6/A0.9311.39656-N-21G06-1E3L-(HC)-HR/A0.9311.396511/2-P-21D07-1E3-(HC)-H9/A0.9311.39658-P-21C02-1E3-(HC)-H6/A0.9311.39658-P-21C05-1E3-(HC)-H6/A0.9311.39656-V-21G01-1C2B/A0.9311.3965A098-P-21D03-1E21-(HC)-H2/A3.8345.7515.8MPa8-P-21D02-1E3-(HC)-H6/A3.8345.7518-P-21D08-1E3-(HC)-H6/A3.8345.751A108-P-21C03-1E21-(HC)-H2/A3.8345.7515.8MPa2-P-21D10-1E3-(HC)-H2/A3.8345.7512-P-21D11-1E3-(HC)-H2/A3.8345.7518-P-21D01-1E3-(HC)-H2/A3.8345.7518-P-21D09-1E3-(HC)-H2/A3.8345.751A118-V-21E07-1C15-(PP)-P1/A0.20.31.4MPa6-V-21F01-1E3L-(PP)-P5/A0.9311.39656-V-21F05-1E3L-(PP)-P5/A0.9311.39658-V-21E01-1E3L-(PP)-P4/A0.9311.39658-V-21E03-1E3L-(PP)-P4/A0.9311.39658"-V-21E11-1C15-(PP)-P4/A0.9311.39656-N-21E02-1E3-(HC)-HR/A0.9311.39656-N-21E04-1E3-(HC)-H6/A0.9311.39656-N-21F01-1E3-(HC)-H6/A0.9311.3965A1211/2-LS-96A12-1E57E-(HC)-H5/A1.42.11.5MPa11/2-LS-96A10-1E57E-(HC)-H5/A1.42.12-LS-96A15-1E57E-(HC)-H5/A1.42.13/4-LS-96A13-1E57E-(HC)-H5/A1.42.13/4-LS-96A08-1E57E-(HC)-H5/A1.42.13/4-LS-96A09-1E57E-(HC)-H5/A1.42.13/4-LS-96A11-1E57E-(HC)-H5/A1.42.13/4-LS-96A14-1E57E-(HC)-H5/A1.42.111/2-N-96A12-1C13/A0.9311.396511/2-N-96A10-1C13/A0.9311.39652"-N-96A15-1C13/A0.9311.39653/4-N-96A13-1C13/A0.9311.39653/4-N-96A08-1C13/A0.9311.39653/4-N-96A09-1C13/A0.9311.39653/4-N-96A11-1C13/A0.9311.39653/4-N-96A14-1C13/A0.9311.39653/4-PA-96A11-1B2-/A11.511/2-PA-96A12-1B2/A11.511/2-PA-96A10-1B2/A11.52-PA-96A15-1B2/A11.53/4-PA-96A13-1B2/A11.53/4-PA-96A08-1B2/A11.53/4-PA-96A09-1B2/A11.53/4-PA-96A14-1B2/A11.51/2-SC-96A13-1C53D-(PP)-P4/A0.6550.98251/2-SC-96A11-1C53D-(PP)-P4/A0.6550.98251/2-SC-96A14-1C53D-(PP)-P4/A0.6550.982511/2-SC-96A15-1C53D-(PP)-P4/A0.6550.9825A131-P-98B21-1C15/A0.9311.39651.4MPa1-P-98B22-1C15/A0.9311.39652-P-98B17-1C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