基本概况
Basic Overview |
容器名称
The name of the container | 残余气体级间洗涤器
Residual gas interstage scrubber | 容器类别
Container category | Ⅲ类
Class III |
图 号
Figure number | V097-00 | 结构型式
Structural type | 立式 □卧式
Vertical □ horizontal |
品 种
Species | □反应 □换热器 □分离 ■储存
□ Reaction □ heat exchanger □ separation ■Storage |
基本设计参数和操作工况
Basic design parameters and operating conditions |
| ■单层
■Single-layer | □管程
□ pipes □内胆
□ liner | □壳程
□ shell process □夹套
□ jacket |
压力
pressure （MPa） | 设计压力
Design pressure | 8.96 | | |
| 操作压力
Operating pressure | 4.38 | | |
温度
temperature （℃） | 设计温度
Design temperature | 66 | | |
| 操作温度
Operating temperature | 46 | | |
主要承压件材料
The main pressure-bearing part material | Q345R、16MnⅢ、16MnⅣ | | |
介质名称及组分
Media name and composition | 天然气
natural gas | | |
最低设计金属温度℃
Minimum design metal temperature °C | 0 | | |
腐蚀裕量 mm
Corrosion margin mm | 1.6 | | |
介质特性
Media characteristics | 毒性危害
Toxic hazards | 无毒
innocuity | | |
| 爆炸危害
Explosion hazards | 易爆
Explosive | | |
容积（m3）
Volume (m3). | 8.79 |
主要受压元件材料
The main pressure element material | 筒体
Cylinder | 封头
Header | 内件
Internals |
| Q345R（正火）
Q345R (normalizing). | Q345R（正火）
Q345R (normalizing). | 无 |
结构型式
Structural type | 立式 □ 卧式 □ 其它
Vertical □ Horizontal □ Other |
设计考虑外载荷
The design takes into account external loads | ■自重 ■风载 □雪载 ■地震载荷□偏心载荷 □其他载荷
■Self-weight ■Wind load □ snow load ■Seismic load □ eccentric load □ other loads |
| 基本风压（N/m2）
Basic wind pressure (N/m2). | 地震设防烈度（加速度）
Seismic fortification intensity (acceleration) | 场地土类别/地面粗糙度
Site Soil Category/Ground Roughness |
| 300 | 7(0.1g) | Ⅱ类/B类
Class II./Class B |
安全附件
Safe Attachments | 类型
type | 型号
Model | 动作压力
Action pressure |
| ■安全阀
■Safety valve | / | / |
| □爆破片
□ rupture discs | | |
设计工况条件下可能发生的失效模式
Failure modes that can occur under design conditions |
■强度失效 ■刚度失效 ■ 密封失效 ■均匀腐蚀减薄
■Strength failure ■Stiffness failure ■ Seal failure ■Uniform corrosion thinning |
不同失效模式控制的措施
Measures for the control of different failure modes |
本设备的设计、制造、安装、改造、维修、使用、检验检测及定期减压均按照TSG 21-2016《固定式压力容器安全技术监察规程》、GB/T150.1～150.4-2011《压力容器》中的各项规定执行。
The design, manufacture, installation, transformation, maintenance, use, inspection and testing and regular pressure reduction of this equipment are carried out in accordance with the provisions of TSG 21-2016 "Regulations for Safety and Technical Supervision of Fixed Pressure Vessels" and GB/T150.1~150.4-2011 "Pressure Vessels". 2、操作及水压试验时，设备内应缓慢升压。
2. During operation and hydrostatic test, the pressure in the equipment should be slowly boosted. |
■韧性断裂（强度失效）控制的措施
■Measures to control ductile fracture (strength failure). |
1、筒体与封头的材料选用Q345R低合金钢板，其化学成分、机械性能及冲击值应符合GB/T 713-2014《锅炉和压力容器用钢板》的要求，筒体、封头交货状态为正火，并按NB/T 47013.3-2015进行超声检测，I级合格。
1. The material of the cylinder and the head is made of Q345R low-alloy steel plate, and its chemical composition, mechanical properties and impact value should meet the requirements of GB/T 713-2014 "Steel Plate for Boilers and Pressure Vessels", and the delivery state of the cylinder and head is normalized, and ultrasonic testing is carried out according to NB/T 47013.3-2015, and the grade I is qualified. 2、合理的设计结构以避免应力集中，包括焊接接头形式，接管内伸应倒圆等；
2. Reasonable design structure to avoid stress concentration, including the form of welded joints, the inner extension of the pipe should be rounded, etc.; 3、采用合理的焊接工艺施焊；
3. Adopt a reasonable welding process for welding; 4、筒体焊后消除应力热处理；
4. Stress relief heat treatment after cylinder welding; 5、设备的焊缝采用全焊透的焊接结构，所有焊缝表面均应圆滑过渡， DN≥200mm开口接管与壳体的角焊缝还应进行超声检测，I级合格； DN＜200mm开口接管与壳体的角焊缝及E类焊接接头还应进行100%MT检测，I级合格；
5. The weld of the equipment adopts a fully penetrated welding structure, and all weld surfaces should be smoothly transitioned, and the fillet weld of DN≥200mm open pipe and shell should also be ultrasonic tested, and grade I is qualified; DN<200mm fillet weld and class E weld joint of the open pipe and the shell should also be 100% MT tested, and the grade I is qualified; 6、法兰等密封元件合理选材、选型，满足设计要求；
6. Reasonable selection of materials and types of sealing components such as flanges to meet the design requirements; 7、按产品制造工艺进行制造，不得强力组对和控制错变量、棱角度。
7. Manufacture according to the product manufacturing process, and do not strongly assemble and control the wrong variables and edges. 8、进行耐压试验。
8. Withstand voltage test. |
■刚度失效控制的措施
■Measures to control stiffness failure |
1、由压力、温度载荷形成的超量变形引起的接头泄漏时应采用以下措施：
1. The following measures should be taken when the joint leakage caused by excessive deformation caused by pressure and temperature load: 1）减少容器在敏感的温度环境中的暴露时间；
1) Reduce the exposure time of the container in a sensitive temperature environment; 2）设计选材应满足设计要求，采用含一定量相关有利元素的低合金钢；
2) The design material selection should meet the design requirements, and the low-alloy steel containing a certain amount of relevant favorable elements should be used; 3）法兰等所有密封要求的零部件取在设计温度下控制微量变形的许用应力强度值。
3) All sealing requirements such as flanges are taken as allowable stress strength values to control the slight deformation at the design temperature. 2、由机械载荷形成的超量变形引起的接头泄露时应采取以下措施：
2. The following measures should be taken when the joint leakage caused by excessive deformation caused by mechanical load: 1）降低表面粗糙度，避免工卡具划痕或刀痕；
1) Reduce the surface roughness and avoid scratches or knife marks of the fixture; 2）对易损零部件定期检查并及时更换劣化失效的易损密封元件，如垫片、紧固件等。
2) Regularly inspect the vulnerable parts and replace the deteriorated and failed vulnerable sealing elements, such as gaskets, fasteners, etc., in a timely manner. 3）法兰等有密封要求的零部件设计压力满足以控制微量变形的材料许用应力强度值为基础的设计要求。
3) The design pressure of flanges and other parts with sealing requirements meets the design requirements based on the allowable stress intensity value of the material to control the slight deformation. |
■密封失效控制的措施
■Measures to control seal failures |
1、密封面不得有任何引起密封失效的裂纹及划痕等损伤；
1. The sealing surface shall not have any cracks and scratches that cause seal failure; 2、出现密封元件失效时及时更换。
2. Replace the sealing element in time when it fails. |
■均匀腐蚀减薄控制的措施
■Measures to control uniform corrosion thinning |
1、外表面采用能阻隔大气腐蚀的油漆或涂料防腐；
1. The outer surface is made of paint or coating that can block atmospheric corrosion; 2、本设备的受压元件的腐蚀裕量，满足在正常操作情况下设计年限内安全运行。
2. The corrosion margin of the pressure element of this equipment meets the safe operation within the design life under normal operation conditions. |
■设计载荷和安全系数的考虑
■Consideration of design load and safety factor |
考虑了压力、温度、自重风载荷和地震载荷，其中安全系数以按照TSG21-2016《固定式压力容器安全技术监察规程》选取。
Pressure, temperature, self-weight wind load and seismic load are considered, and the safety factor is selected in accordance with TSG21-2016 "Safety Technical Supervision Regulations for Fixed Pressure Vessels". |
■介质特性：本设备的介质为氮气，无毒不易爆。因此对以下情形采取相应措施：
■Medium characteristics: The medium of this equipment is nitrogen, which is non-toxic and non-explosive. Therefore, appropriate measures are taken in the following cases: |
可能发生的危害和处置措施
Hazards that may occur and measures to deal with them |
■使用中发生少量泄漏
■A small amount of leakage occurs during use | 处置措施
Disposal measures | 操作人员按安全操作规程关闭相关阀门、设备，先期按已制定的堵漏工艺处置，并立即通知单位管理、维修、应急抢险人员到场。指挥人员根据情况是否启动单位应急预案。
The operator shall close the relevant valves and equipment according to the safety operation procedures, dispose of the leakage plugging process in advance, and immediately notify the unit management, maintenance and emergency rescue personnel to arrive at the scene. The commander shall activate the unit's emergency plan according to the situation. |
■使用中发生大量泄漏和涌出
■A large amount of leakage and gushing occurs during use | 处置措施
Disposal measures | 当发生大量泄漏，或事态无法控制，或有迹象表明事态趋各失控时应立即报警，当地政府应急指挥人员决定是否启动本地区的应急预案。
When a large number of leaks occur, or the situation is out of control, or there are signs that the situation is getting out of control, the police should be called immediately, and the local government emergency commander decides whether to activate the emergency plan in the area. |
■爆炸
■ Explosion | 处置措施
Disposal measures | 1、根据爆炸灾害后果预测，制定爆炸应急预案并进行演练，包括：组织领导、报警和上报、人员疏散和人员抢救、防护用具正确使用、关阀断源、消防器材正确使用；稀释周围扩散空气中的介质浓度，以防止与空气或其他禁忌介质混合形成二次爆燃或爆炸；
1. According to the prediction of the consequences of the explosion disaster, formulate the explosion emergency plan and conduct drills, including: organization and leadership, alarm and reporting, personnel evacuation and personnel rescue, correct use of protective equipment, valve closure and source cut-off, and correct use of fire-fighting equipment; dilute the concentration of the medium in the surrounding diffused air to prevent the formation of a secondary deflagration or explosion when mixed with air or other contraindicated media; 2、出现爆炸按应急预案科学指挥和实施。
2. In the event of an explosion, it shall be scientifically commanded and implemented according to the emergency plan. |
人员、防护设备要求和措施
Requirements and measures for personnel, protective equipment |
人员要求
Personnel requirements | 1、制定严格的管理制度和事故预防预案；
1. Formulate strict management systems and accident prevention plans; 2、对与其相关的人员，包括应急救援人员，对关键操作人员、维修人员应培训考核合格后上岗。
2. For its related personnel, including emergency rescue personnel, key operators and maintenance personnel should be trained and assessed before taking up their posts. |
防护设备
Protective equipment | 1、应配备：堵漏设备及设施；防护服；接地电阻测试仪；消防器材并在有效期内；装卸防静电火花措施；设备避雷装置。
1. It should be equipped with: plugging equipment and facilities; Protective clothing; Earth Resistance Tester; fire-fighting equipment and within the validity period; anti-static spark measures for loading and unloading; Equipment lightning protection device. 2、对动力源、动力线路及照明装置应采取防爆或隔爆措施。
2. Explosion-proof or flameproof measures should be taken for power sources, power circuits and lighting devices. 3、划分控制区和非控制区并有警示标识或标志。
3. Divide the control area and the non-control area and have warning signs or signs. |
建造、使用过程中的损伤及预防措施
Damage and preventive measures during construction and use |
制造
fabricate | 影响损伤的关键因素
Key factors influencing the injury | 未按规定制造和组装，焊接接头缺陷超标及几何尺寸不符合要求。
Failure to manufacture and assemble according to the regulations, welded joint defects exceed the standard and geometric dimensions do not meet the requirements. |
| 预防损伤的建议措施
Recommended measures to prevent injury | 1、严格按设计文件及产品的制造工艺进行制造，做到不强力组装和控制错边量、棱角度；
1. Manufacture in strict accordance with the design documents and the manufacturing process of the product, so as to achieve no strong assembly and control of the amount of misalignment and edges; 2、对接接头、角接接头应按相关规定进行焊接工艺评定，按施焊工艺施焊，确保焊接接头内外部质量及几何尺寸。
2. Butt joints and angle joints should be evaluated for welding process according to relevant regulations, and welded according to the welding process to ensure the internal and external quality and geometric dimensions of welded joints. |
起吊
Lifting | 影响损伤的关键因素
Key factors influencing the injury | 撞伤、失圆超标、坠落。
Bumps, out-of-rounds, falls. |
| 预防损伤的建议措施
Recommended measures to prevent injury | 起吊人员应持证上岗并吊装方案和起吊规程操作，起吊前应检查起吊设备和吊具的安全可靠性，起吊时应尽量保持起吊重心与设备重心一致。
Lifting personnel should be certified to work and hoisting program and lifting procedures operation, before lifting should check the safety and reliability of lifting equipment and spreaders, lifting should try to keep the lifting center of gravity and equipment center of gravity consistent. |
运输
transport | 影响损伤的关键因素
Key factors influencing the injury | 碰撞、跌落。
Collisions, falls. |
| 预防损伤的建议措施
Recommended measures to prevent injury | 运输中，设备应固定牢固，尽量不超载，对超高和超宽运输的应有防护措施。
During transportation, the equipment should be fixed firmly, try not to overload, and there should be protective measures for ultra-high and ultra-wide transportation. |
检验
Inspection | 影响损伤的关键因素
Key factors influencing the injury | 漏检、误检和误判
Missed detections, false detections, and misjudgments |
| 预防损伤的建议措施
Recommended measures to prevent injury | 应制定检验管理制度和检验规程或计划，检验人员应培训上岗，按规定检验、试验并记录、报告且数据准确可靠和可追溯。
Inspection management systems and inspection procedures or plans should be formulated, and inspectors should be trained to work, and inspection, testing, recording, and reporting should be carried out according to the regulations, and the data should be accurate, reliable and traceable. |
安装
Installation | 影响损伤的关键因素
Key factors influencing the injury | 安装不当，引起损伤超标和附加约束反力增大及排污不畅。
Improper installation will cause excessive damage, increased reaction force and poor sewage discharge. |
| 预防损伤的建议措施
Recommended measures to prevent injury | 1、应具有安装资质的单位进行安装；
1. The installation should be carried out by a unit with installation qualifications; 2、安装前应按系统图制订安装工艺并履行审批；
2. Before installation, the installation process should be formulated according to the system diagram and the approval should be performed; 3、安装时控制管道接口与设备接口的刚性约束以及支座与基础连接时应留有一定的伸缩量，设备就位时应沿纵轴线按图样规定呈倾斜度就位；使排污口处于最低点；
3. During installation, the rigid constraints of the control pipeline interface and the equipment interface and the connection between the bearing and the foundation should be left with a certain amount of expansion and contraction, and the equipment should be in place along the longitudinal axis according to the layout when the equipment is in place; Keep the outfall at its lowest point; 4、安装后投运前应按规定检验、试验（监检）并记录、报告。
4. After installation, it should be inspected, tested (supervised and inspected) and recorded and reported according to the regulations before it is put into operation. |
操作
operate | 影响损伤的关键因素
Key factors influencing the injury | 1、不按规定的工况操作或误操作；
1. Failure to operate or misoperate according to the specified working conditions; 2、安全附件失灵。
2. The safety attachment is out of order. |
| 预防损伤的建议措施
Recommended measures to prevent injury | 1、制定安全管理制度和操作规程；
1. Formulate safety management system and operating procedures; 2、操作人员上岗前应培训合格；
2. Operators should be trained and qualified before taking up their posts; 3、按操作规程操作并记录且数据可靠和具追溯性；
3. Operate and record according to operating procedures, and the data is reliable and traceable; 4、严禁超压、超温、超载操作；
4. It is strictly forbidden to operate with overpressure, temperature and overload; 5、经常检查安全附件的可靠性和灵敏度；
5. Always check the reliability and sensitivity of safety accessories; 6、设备巡检人员应密切关注与设备有关的配件设施，发现问题及时处理，分析原因，不可带病服役。
6. Equipment inspection personnel should pay close attention to the accessories and facilities related to the equipment, deal with the problems in time, analyze the causes, and do not serve with illness. |
使用说明及注意事项：
Instructions and precautions for use: 1、按《固容规》要求在使用前登记注册；
1. Register before use according to the requirements of the "Solid Capacity Regulations"; 2、应制定安全使用管理制度和操作规程；
2. The management system and operating procedures for safe use should be formulated; 3、对装卸物料的操作人员应进行岗位培训并严格按操作规程操作且记录；
3. The operators of loading and unloading materials should be trained on the job and operated and recorded in strict accordance with the operating procedures; 4、最大压力不得超过图样规定的设计压力；
4. The maximum pressure shall not exceed the design pressure specified in the drawing; 5、定期或不定期检查安全附件（含仪表）是否失灵，是否在有效期内；
5. Regularly or irregularly check whether the safety accessories (including instruments) are out of order and whether they are within the validity period; 6、对容易发生泄漏处应经常检查，发现泄漏应立即按应急预案进行实施；
6. The leakage points should be checked frequently, and the leakage should be implemented immediately according to the emergency plan; 7、操作与维护应由有资质及能力的人员进行，操作与维护应具有专用工具，法兰紧固件的紧固应利用力矩扳手等紧固专用工具；
7. The operation and maintenance should be carried out by qualified and capable personnel, and the operation and maintenance should have special tools, and the fastening of flange fasteners should use special fastening tools such as torque wrenches; 8、 用户应控制工艺操作参数在正常范围内；
8. The user should control the process operation parameters within the normal range; 9、设备安装时应合理支撑，应有效静电接地；
9. When the equipment is installed, it should be reasonably supported and effectively grounded electrostatically; 10、操作状态下，用户应防止紧固及松动容器上的螺母、螺栓；
10. In the operating state, the user should prevent tightening and loosening the nuts and bolts on the container; 11、操作状态下，不应敲击容器；
11. In the operating state, the container should not be knocked; 12、用户应使外防腐涂层保持良好状态，定期进行外防腐；
12. The user should keep the external anti-corrosion coating in good condition and carry out external anti-corrosion regularly; 13、停止检修时应把容器内的残余气体置换干净后再打开容器；
13. When stopping maintenance, the residual gas in the container should be replaced before opening the container; 14、在控制区内禁止明火。
14. Open flames are prohibited in the control area. 15、定期进行壁厚检测和内壁腐蚀情况检查。
15. Regularly carry out wall thickness testing and inner wall corrosion inspection. |
维修中的注意事项：
Precautions in maintenance: 1、维修单位应具有相应维修资质，维修过程应接受质检部门的监督；；
1. The maintenance unit shall have the corresponding maintenance qualifications, and the maintenance process shall be subject to the supervision of the quality inspection department; 2、维修前内部清洗置换；
2. Internal cleaning and replacement before maintenance; 3、制定维修方案并按规定审批，并明确维修处不得有人为的损伤和结构的不连续性，且确保设备本质安全符合规定要求；
3. Formulate a maintenance plan and approve it according to the regulations, and make it clear that there shall be no man-made damage and structural discontinuity in the maintenance department, and ensure that the intrinsic safety of the equipment meets the specified requirements; 4、按维修方案实施和检验、试验（含监检）并记录、报告。
4. Implement and inspect and test (including supervision and inspection) according to the maintenance plan, and record and report. |
改造中的注意事项：
Precautions in retrofit: 1、承担改造的单位应具有相的改造资质，改造过程应接受质检部门的监督；
1. The unit undertaking the transformation should have the corresponding transformation qualifications, and the transformation process should be subject to the supervision of the quality inspection department; 2、改造前内部清洗置换；
2. Internal cleaning and replacement before transformation; 3、制定改造方案并按规定审批，并确保改变的运行参数或材料或结构及尺寸应满足设备本质安全的要求；
3. Formulate a transformation plan and approve it according to the regulations, and ensure that the changed operating parameters or materials or structure and size should meet the requirements of the intrinsic safety of the equipment; 4、按改造方案实施和检验、试验（含监检）并记录、报告
4. Implement and inspect and test (including supervision and inspection) according to the transformation plan, and record and report |
补充说明：为了保障设备的安全，对于设备建造、使用过程中的风险评估及控制还需要制造、安装、维修单位及用户根据实际情况和经验进行相关评估
Supplementary note: In order to ensure the safety of the equipment, the risk assessment and control in the process of equipment construction and use also need to be evaluated by the manufacturing, installation, maintenance units and users according to the actual situation and experience |
