挠性软管管理程序

1、苏州翰普-挠性软管管理程序Suzhou HiPro Flexible Hose Management Procedure文件编号Code:G-3-MAIN-001Rev: 01Effective Date: Aug 01, 2014Page 14 of 14- 14 -通用文件General发布至DISTRIBUTION TO苏州翰普Suzhou HIPRO人事行政部 HR & Admin department (0) 聚合改性生产部Polymer&Compounding Production (3) o 总经理GM 改性车间 Compounding o 人事行政HR & Admin 聚合车间

2、 Polymerization质量部 Quality department (1) oDCS控制室 DCS control room QC实验室 QC Lab 公用工程Utility o QA 技术部Technical department (2) 供应链部 Supply chain department (0) 维修Maintenance 采购 Purchasing 战略 Strategy 仓库 Warehouse 健康安全及环保HSE department(1) 物流 Logistics 健康安全及环保HSE 财务部Finance department (0) o危机管理中心CMC癸二胺生

3、产部 DA10 Production (2)工艺部 Process department(0) 制腈车间 Nitrilation 加氢车间 Hydrogenation o DCS控制室 DCS control room纸质版发放地点_存档部门：苏州翰普体系管理 For Filing: Suzhou Hipro, system management service 起草人Prepared by审核人Reviewed by批准人Approved by职务 FunctionInsp.EngineerReliability EngineerTechnical Mgr.姓名 Name Guoping X

4、uChris SunWilliam Zhang签名Signature修改记录Record of Document Modification版本Rev.日期Date主要更改Principal modifications 更改人 Modifier批准人Approval01Aug 01, 2014First issueGuoping XuWilliam Zhang1. Purpose目的This procedure describes how to select, use and inspect flexible hoses on Arkema SuZhou Hipro site, to ensur

5、e that all hoses are in good condition, used correctly and to minimize the risk of incident or injury to employees.本程序描述了在阿科玛苏州翰普基地如何选择、使用和检查软管，以确保所使用的软管状态良好、使用正确，从而减少事故的可能性或对员工的伤害。2. Scope范围This procedure is applicable for loading/unloading hoses & other chemical hoses, utility hoses, equipment tes

6、ting hoses and quick couplings on Arkema SuZhou Hipro site. The other hoses used in technical workshop (welding gas, insert gas), HSE deportment (breathing air hoses, fire water hoses), lab and for electrical/ instrument devices were excluded in this procedure. If hoses are used and owned by contrac

7、tors, the contractor has the responsibility to ensure that their own hoses are in good condition and to tag an identification label on the hose during using.本程序适用于阿科玛苏州翰普基地上使用的装卸用软管和其它化学品软管、公用工程软管、设备试验用软管及快速接头。本程序不包括维修车间、电仪、安全部、实验室等使用的其它软管（焊接用气体软管、氧气乙炔气体软管、呼吸空气软管、消防水管）。承包商在阿科玛翰苏州普基地使用自有的软管时，必须确保软管处于

8、良好状态，并挂牌使用。3. Reference参考Flexible Metal Hose Inspection Regulations波纹金属软管检验规程 SB4-2006（试行）Pressure Vessels Periodical Inspection Regulation压力容器定期检验规则TSG R7001-2010Supervision Regulation on Safety Technology for Transportable Pressure Vessel 移动式压力容器安全技术监察规程TSG R0005-2011Transportable Pressure Vessel

9、Filling Licensing Regulation移动式压力容器充装许可规则 TSG R4002-2001Pressure Pipe Element Type Test Regulation 压力管道元件型式试验规则TSG D7002-2006General Technical Conditions of the Metal Hose波纹金属软管通用技术条件GB/T14525-934. Definition定义4.1 Loading/unloading hoses and quick couplings 装卸用软管和快装接头Loading/unloading hoses and quic

10、k couplings are used for filling of transportable pressure vessel or for unloading of chemical raw material, and it must be reliably connected.指专门用于移动式压力容器充装或化学品原料卸料的软管和快装接头，且连接应当可靠。4.2Utility hoses and quick coupling 公用工程软管和快装接头Rubber hoses and quick couplings are used in utility stations. Possible

11、 mediums are steam, water, plant air and nitrogen. Utility hoses are not allowed to use for chemicals. It is forbidden to use water hoses for steam and interchange air and nitrogen hoses. Especially, in order to avoid the mix using, the nitrogen hoses and breathing hoses are installed with the diffe

12、rent special connecters. 指公用工程使用的橡胶软管及快装接头，通常适用于蒸汽、水，压缩空气和氮气等介质。公用工程软管不能用于化学品输送。水软管不能当蒸汽软管用，也不能和压缩空气和氮气软管混用。特别地，氮气软管和呼吸空气软管分别采用不同的专用连接接头，以免混用。4.3 Other chemical hoses 其它化学品软管Chemical hoses are used for chemicals according to process requirements and two sides were fixed connected. These hoses have t

13、o be qualified and certified for the usage of chemicals. The hoses can e.g. be made of stainless steel, stainless steel with PTFE liner, special rubber or multiple materials. PVC hose is forbidden for use with chemical products or highly polluted waste water.指应工艺需求，用于生产过程中化学品输送的软管，且两端是固定连接的。这些软管应是合格

14、的，并被证明可用于化学品。可采用不锈钢， 或不锈钢内衬PTFE，或特种橡胶，或复合材料制成。PVC软管不准用于化学品和高度污染的废水的输送。4.4Hose labeling 软管标识4.4.1 Utility hoses have to be labeled with color identification to avoid operation mistakes. (see table 1).为避免误操作 ，厂区内所有的公用工程软管必须使用规定的色标加以识别（见表1）。Table 1, Color IdentificationMedium介质Identification Color辨别色N2

15、 氮气Rape Yellow油菜黄Compress Air压缩空气Sky Blue天蓝色Steam蒸汽Dull Red暗红色Water水Light Green浅绿色The color identification can be applied by a color tag attached to the hose or by color paint or even using colored hoses.色标可以通过在软管末端悬挂色签，或涂色漆，或选用有色软管等。4.4.2 For chemical hoses it is mandatory to label the hoses with a

16、 tag which contains the below information as minimum to identify the status of the hoses :厂区内所有化学品软管必须加附标签以识别软管的状态，标签上至少应含有以下信息：Unit单元Flexible hose No (stamp on the side of flange or nozzle)软管编号（铭刻在软管法兰或接头侧面）Medium介质名称Size规格Work pressure工作压力Test pressure测试压力Start up date (stamp on the side of flange

17、 or nozzle)开始使用日期（铭刻在软管法兰或接头侧面）Inspection date检查日期Next inspection date下次检查日期4.4.3 检验色标 After the hose has been inspected and confirmed in good condition. The inspection identification color mark shall be painted on the flange neck or the nozzle of hose. The color marks are as follows: Red in 2014; Y

18、ellow in 2015; Green in 2016; Black in 2017; White in 2018. After these five colors will be used by circulation. 软管验完且确认完好后，在软管法兰颈部或接头颈部涂年度校验颜色识别标记。标记颜色如下：红色 2014年；黄色 2015年；绿色 2016年；黑色 2017年；白色2018年。种颜色进行循环。5. Responsibilities责任Production and logistics department uses flexible hoses. Technical Depar

19、tment is responsible for making flexible hose usage period, inspection plan and conducting the inspection.生产部和现场物流部负责使用各自的软管，技术部负责制定软管使用年限、检验计划并实施检验。6. Procedure程序6.1 Choice of Hoses and quick couplings 软管和快装接头的选择6.1.1 All hoses must be ordered from qualified suppliers. It is necessary that the owne

20、r provides adequate information to buy the right hoses such as medium description, operation pressure and temperature, nominal diameter, connection type, length, material plus any other information required by the vendors. See “Specification of Flexible Hose”.任何软管必须向合格的供应商订购，为确保买到正确的软管，用户需要提供足够的信息，例

21、如介质说明，软管的工作压力和温度，公称直径，连接方式，长度，材质等，以及供应商需要的其它信息。参见挠性软管技术特性表Especially for loading/unloading hoses and quick couplings settings shall comply with the design drawings and reference standards, the related manufacture certificate must be confirmed before purchasing. And the hoses and quick couplings mate

22、rial can consistent with the filling medium. The nominal pressure of loading/unloading hoses and quick couplings must be more than the double of loading/unloading system pressure; the minimum burst pressure must be more than 4 times the nominal pressure. 特别是装卸用软管和快装接头的设置应当符合设计图样和引用标准的规定，采购前需确认供应商是否具

23、备国家认可的制造资质，所选用装卸用管及快装接头的材料与充装介质要相容。装卸用软管和快装接头的公称压力不得小于装卸系统工作压力的2倍，其最小爆破压力大于4倍的公称压力。6.1.2 For the new purchased hoses and quick couplings, the related person from ARKEMA should check the test report and certification, and check the hoses visually to confirm the quality before hoses storing in warehou

24、se. 对于新采购的软管和快装接头，供应商必须根据要求提供软管试验报告和合格证，经阿科玛相关人员检验合格后方可入库。Especially for loading/unloading hoses and quick couplings, the suppliers need to provide the type test reports by the certification authority according to the relevant provisions of the state. The key is its blast pressure must be more than

25、4 times the nominal pressure. The metal nameplate must be firmly installed on the hose visible position before delivery.特别对于新采购的装卸用软管和快装接头，根据国家相关规定，供应商还需提供获权威机构认证的型式试验报告，关键是其试验时爆破压力要大于4倍公称压力。装卸用软管出厂时应当在产品的明显部位装设牢固的金属铭牌。6.2 Usage of Hoses 软管的使用6.2.1Hoses should be stored on proper hose racks to avoid

26、 damage due to sharp bends. 软管必须存放在合适的架子上，以免剧烈弯折损坏。6.2.2 The user must inspect hoses visually before taking in-service. Proper labeling is precondition for use. Labels will be provided and installed by technical department. 使用人员在软管使用前必须先对软管进行目视检查。正确的标签是软管使用的前提，其标签由技术部相关人员提供及安装。6.2.3 All installation

27、s should: 所有装备必须：A、Avoid sharp bends, twists and excessive flexing. 避免剧烈弯折、扭曲和过度挠曲。B、Minimize the obstruction of walkways. 减少通道上的障碍物 。C、Provide adequate support to avoid overstressing the hoses or couplings. 充分支撑以防软管或接头过度受力。D、Protect the hoses when crossing the road. 当软管横跨过道时，要加适当的保护。6.2.4 Operation

28、 pressure must be less than the design pressure of the hoses. 软管的使用压力必须小于设计压力。For loading /unloading hoses, the nominal pressure should be the double of system pressure.对于装卸用软管，公称压力应该是其系统工作压力的两倍。6.2.5 Operation temperature should follow the recommendation from the hoses vendor.软管的工作温度应遵守软管供应商建议的温度范围

29、。6.2.6If a utility hose is used for connection to a process line or vessel containing chemicals, a double block/relief system in conjunction with a check valve shall be installed. The utility hose must be blown to free of chemical before disconnecting or closing the valve, to avoid chemicals contami

30、nation to utility system. 若公用工程软管被用来连接至含化学品的工艺管线或设备，应安装双隔断/泄放系统及止逆阀。在断开连接或关阀门之前，公用工程软管必须吹扫干净，以避免公用工程系统被化学品污染。6.2.7Any hoses, which are used to transfer or connect to flammable/explosive medium, must be grounded reliably. The grounding must be checked before the hose in service every time.任何软管用于输送或连接

31、至易燃易爆的介质时，软管必须可靠接地。每次使用软管之前必须检查接地情况。6.2.8 The hoses which are used for loading/unloading can be installed immovably or movably. For immovable installations the hoses are regarded as normal pipes with hose number. For movable installations the hoses must be indicated with a tag “loading/unloading onl

32、y”, and stored on the appointed rack.用于装/卸料的软管可以固定安装或移动安装。对固定安装的软管，作为有位号的常规管道对待。对移动安装的软管，应挂标签指明“装/卸料专用”，并存放在指定的货架上。6.2.9 The hose which is used for temporary connection based on process requirement must be stored near the installation position in the field, with a tag indicated special part number,

33、and the number should be same as it on PID drawing.用于工艺要求而临时连接的软管，必须存放在现场靠近安装位置的地方，并挂标签注明特殊备件号，这个编号应和PID图上的编号相同。6.2.10 All hoses must be depressurized before disconnecting from the system.软管必须先降压才可与系统断开连接。6.2.11 Chemical hoses must be emptied, cleaned and dried after in-service, and stored on proper

34、 hoses racks. 化学品软管使用后，必须排净，清洗及干燥，并存放于软管架上。6.3 Inspection and testing 检查和测试6.3.1 Loading/unloading hoses and quick couplings 装卸用软管和快装接头6.3.1.1 After the loading/unloading hoses and quick couplings have been assembled, the pressure test at 1.5 time nominal pressure and leakage test at 1.0 time nomina

35、l pressure should be carried out. 装卸用软管和快装接头组装完成后应当逐根进行耐压试验和气密性试验，耐压试验压力为装卸软管公称压力的1.5倍，气密试验压力为装卸软管公称压力的1.0倍。6.3.1.2 Loading/unloading hoses and quick couplings must be inspected visually by hose-user before taking hoses in-service. At first the information on the tag has to be checked, especially if

36、 the inspection date is overdue. For the visual inspection the following potential defects of the hose have to be inspected. 装卸用软管和快装接头必须由使用人员在使用前进行检查。首先检查标签上的信息，尤其是检查日期是否过期。目视检查应检查软管是否有以下潜在缺陷， a) Metal braid broken 金属编织物破损 b) Metal braid strong corroded 金属编织物腐蚀严重 c) Chemical contamination on the br

37、aid 编织物被化学品污染 d) Hoses blocked or something abnormal inside 软管堵塞或内有异物 e) Quick couplings strong wearing, corroded or cracking 快装接头严重磨损、腐蚀和裂纹 If the inspection date is overdue or existing the potential defects on one hose, dont use it until confirmed by testing or inspection. 如发现检查日期已过期或有潜在缺陷，则停止使用。等

38、重新试验或检验合 格后再使用。6.3.1.3 Loading/unloading hoses must be pressure tested by the owner (BU/Plant workshop) every 6 months according the related regulation. 对装卸用软管，根据规定每半年应进行一次耐压试验。1) Pressure test with 1.5 time nominal pressure 1.5倍公称压力下的压力试验 Demineralized water has to be used as test medium. 采用洁净水作为试验

39、介质 Test devices contain a test pump, a pressure gauge and flange with a exhaust valve.试验装置可包括试压泵，压力表，带排气阀的法兰等。 Hose has to be put on the ground, one end connected to the pump outlet and on the other end shall installed a flange with the exhaust valve. The exhaust valve has to be kept in high positio

40、n.将软管平铺在地面，一端与泵出口连接，另一端安装带排气阀的法兰。保持排气阀在高位。 Start the pump to feed water into the hose, while keep the exhaust valve open. When the air inside the hose is disappeared, the exhaust valve can be closed.启动试压泵将水注入软管，同时打开排气阀。当软管内的空气排尽后，关闭排气阀。 Increase the pressure slowly till to 1.5 time nominal pressure

41、and stop the pump. 缓慢升高压力至1.5倍的公称压力，停泵。 Pressure has to be kept for 5 minutes at least and to check if the hose has any leakage. 保持压力至少5分钟，检查软管是否泄漏。 If the pressure test was completed successfully, the test record has to be completed, and the test date on the tag has to be updated.如果试验合格，完成试验记录，并更新标

42、签上的检查日期。6.3.2 Utility hoses and quick couplings 公用工程软管和快装接头6.3.2.1 All utility hoses and quick couplings must be visually inspected by the hose-user before taking hose in-service. The following defects on outside surface of hoses are not acceptable, and the hoses or quick couplings must be changed.软

43、管和快装接头的使用人员必须在使用前对其进行检查。软管和快装接头外表面的以下缺陷是不可接受的，必须更换。a) Any perforation or crack任何穿孔或裂口b) Exposure of strengthened laye增强层暴露c) Chap by ozone 臭氧导致的龟裂d) Partly distortion局部扭曲变形e) Quick couplings strong wearing, corroded or cracking快装接头严重磨损、腐蚀和裂纹6.3.2.2 When utility hoses are in service the hoses surface

44、 has to be checked. If the hoses show bubbles or an expansion under pressure, the hoses must be changed.软管使用时，检查软管表面。如果软管在承压时起泡或膨胀，必须更换软管。6.3.2.3 It is not mandatory to have a pressure test for utility hoses periodically. Suggest the inspection engineer to do visual checking for these utility hoses

45、yearly, if found the unacceptable defects or the potential defects, the hoses must be changed. 不强求对公用工程软管进行定期的压力测试，建议每年由检验工程师对其进行目视检查，发现不可接受的缺陷或潜在的缺陷要立即更换。6.3.2.4 The user (plant) has to pay attention to the useful life of utility hoses. Normally the recommendation can be found in the vendor instruc

46、tion. For example if the hoses are recommended to be used for 5 years, the hoses should be exchanged after 5 years, even if there are no obvious defects on the hose surface. Therefore a proper label is required. 生产装置应注意软管的使用寿命。通常软管的供应商可以提供相关建议。例如，如果软管的使用寿命建议为5年，那么5年后软管应予以更新，即使软管的表面没有明显的缺陷。因此，这也要求挂有合

47、适的识别标牌。6.3.3 Other chemical hoses 其它化学品软管6.3.3.1 Chemical hoses also must be inspected visually by hose-user before taking hoses in-service. At first the information on the tag has to be checked, especially if the inspection date is overdue. For the visual inspection the following potential defects

48、of the hose have to be inspected化学品软管同样也必须由使用人员在使用前进行检查。首先检查标签上的信息，尤其是检查日期是否过期。目视检查应检查软管是否有以下潜在缺陷， a) Metal braid broken 金属编织物破损 b) Metal braid strong corroded 金属编织物腐蚀严重 c) Chemical contamination on the braid 编织物被化学品污染 d) Hoses blocked or something abnormal inside 软管堵塞或内有异物 If the inspection date is

49、 overdue or existing the potential defects on one hose, dont use it until confirmed by testing or inspection. 如发现检查日期已过期或有潜在缺陷，则停止使用。等重新试验或检验合格后再使用。6.3.3.2 The other movable chemical hoses must be pressure tested by the owner (BU/Plant workshop) every 12 months. The hose between a movable pressure v

50、essel and a stationary pressure vessel, where the hose is used for loading /unloading, must be pressure tested every half year. For immovable chemical hoses the test interval is specified individually by the owner depending on the application (e.g. together with the system the hoses are used for). 移

51、动安装的其它化学品软管每12个月应由本厂维修部门进行压力试验。固定安装的软管，其试压周期由用户根据使用情况自行确定。A) Pressure test with 150% nominal pressure 1.5倍公称压力下的压力试验A1. Demineralized water has to be used as test medium. 采用洁净水作为试验介质A2. Test devices contain a test pump, a pressure gauge and flange with a exhaust valve.试验装置可包括试压泵，压力表，带排气阀的法兰等。 A3. Ho

52、se has to be put on the ground, one end connected to the pump outlet and on the other end an installed flange with exhaust valve. The exhaust valve has to be kept in high position.将软管平铺在地面，一端与泵出口连接，另一端安装带排气阀的法兰。保持排气阀在高位。A4. Start the pump to feed water into the hose, while keep the exhaust valve ope

53、n. When the air inside the hose is disappeared, the exhaust valve can be closed.启动试压泵将水注入软管，同时打开排气阀。当软管内的空气排尽后，关闭排气阀。A5. Increase the pressure slowly till to 150% nominal pressure and stop the pump. 缓慢升高压力至1.5倍的公称压力，停泵。A6. Pressure has to be kept for 5 minutes at least while checking if the hose has

54、 any leakage. 保持压力至少5分钟，检查软管是否泄漏。A7. If the pressure test was completed successfully, the test record has to be completed, and the test date on the tag has to be updated.如果试验合格，完成试验记录，并更新标签上的检查日期。B) Pressure test with 110% nominal pressure 1.1倍公称压力下的压力试验B1. For hoses which are used for chemicals which have to be free of water, the hoses can be tested with test gas. 对某些要求禁水的化学品，软管可按此法进行试验。B2. Nitrogen has to be used as test medium.