GB 50461-2008 English PDF

GB 50461-2008: Code for quality acceptance of static equipment installation in petrochemical engineering
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GB 50461-2008
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
UDC
P GB 50461-2008
Code for Construction Quality Inspection and Acceptance
Specification of Petrochemical Static Equipment Installation
ISSUED ON: NOVEMBER 12, 2008
IMPLEMENTED ON: MAY 1, 2009
Issued by: Ministry of Housing and Urban-Rural Construction of the People’s
Republic of China;
General Administration of Quality Supervision, Inspection and
Quarantine of the People’s Republic of China.
Table of Contents
Foreword ... 4
1 General Provision ... 8
2 Terms ... 9
3 Basic Requirements ... 10
3.1 Qualification Requirements... 10
3.2 Counting Devices ... 10
3.3 Supervision and Inspection for Pressure Vessel Installation Work ... 10
3.4 Technical Documents of Equipment Installation ... 10
3.5 Uncasing Inspection for Equipment ... 11
3.6 Validation and Designation of Installing and Measuring Basis of the Equipment ... 12
3.7 Protection for Finished Product and Semi-manufactured Goods ... 13
4 Equipment Installation ... 14
4.1 Foundation Repetition Measurement and Treatment ... 14
4.2 Anchor Bolts ... 18
4.3 Sizing Blocks ... 18
4.4 General Rules of Installation ... 19
4.5 Grouting ... 22
4.6 Installation of Internal Components ... 23
4.7 Installation of Safety Accessories ... 23
4.8 Installation of Platform and Ladder ... 23
4.9 Cleaning, Liquidating and Sealing ... 24
5 On-site Welding for Equipment ... 27
5.1 General Requirements ... 27
5.2 Inspection of Assembling Component ... 28
5.3 Assembling ... 37
5.4 Welding ... 41
5.5 Heat Treatment ... 43
5.6 Shape Dimension and Appearance Inspection of Soldered Joint ... 45
5.7 Nondestructive Testing ... 47
5.8 The Overall Shape and Dimensional Inspection of Equipment ... 50
6 Test ... 52
6.1 General Requirements ... 52
6.2 Hydraulic Test ... 54
6.3 Gas Pressure Test ... 55
6.4 Airtight Test ... 55
6.5 Water filling leak-off-test or kerosene leak-off-test ... 56
7 Project Completions ... 57
Appendix A Flat Sizing Block and Skew Sizing Block ... 59
Appendix B The Quality Standard of Structure Installation of Air Cooled Exchanger ... 61
Appendix C The Quality Standard of Internal Component Installation of Tower Type Equipment
... 62
1 General Provision
1.0.1 This code is formulated with a view to strengthen the quality control of petrochemical
construction work, unify the requirements of installation work construction acceptance for
petrochemical static equipment (hereinafter referred to as “equipment”) and guarantee the
quality for equipment installation.
1.0.2 This code is applicable to the construction quality inspection and acceptance for
equipment installation of petrochemical construction work integral installation equipment and
on-site welding equipment and their special internal components, safety accessories, adjunctive
ladder and platform of equipment.
This code is not applicable to the construction quality inspection and acceptance for vertical
type cylindrical tank, gas tank and nonmetal equipment.
1.0.3 Overall inspection is required for all articles except the ones which are indicated with
the inspection quantity in this code.
1.0.4 Not only the requirements stipulated in this standard, but also those in the current
relevant ones of the nation shall be complied with for the construction quality inspection and
acceptance for the equipment installation.
3 Basic Requirements
3.1 Qualification Requirements
3.1.1 The construction organizations that are employed in equipment installation, on-site
welding and nondestructive testing works shall be staffed with the corresponding professionals
who are competent for the works they are in charge with.
Check method: Check the enterprise qualification certificate.
3.1.2 The staff who is employed in equipment welding and nondestructive inspection work
shall take the examination according to the current national standard and provision
requirements and obtain the relevant certificates, and the competent staff can be employed in
the works which are corresponding to their qualifications.
Check method: Check the staff’s qualification certificate.
3.2 Counting Devices
3.2.1 The counting device shall be calibrated, adjusted or verified, and in the qualified state,
the device also shall be used in the effective and determining period.
Check method: Check the test marks of the counting device.
3.2.2 When the cycle certified counting device is transferred, the calibrating/adjusting
certificate shall be required.
Check method: Check the verification certificate of the counting device.
3.3 Supervision and Inspection for Pressure Vessel Installation Work
3.3.1 As for the pressure vessel on-site welding and installation work, the employed
construction organization shall notify the local special equipment safety supervisory
department for inspection in writing before commencement.
Check method: Check “the Special Equipment On-site Welding and Installation Notice”.
3.3.2 As for the pressure vessel on-site welding and installation work, the employed
construction organization shall accept the supervision and inspection from the inspection and
detection organization which takes the qualification on the work place.
Check method: Check “The Installation Quality Certificate of Boiler Pressure Vessel”,
and “Safety Performance Supervision Testing Certificate for Boiler Pressure Vessel
Products”.
3.4 Technical Documents of Equipment Installation
3.4.1 The equipment installation shall be equipped with the following technical documents:
1 After pickling and passivating and it is washed, the 0.01% methyl orange extract
solution shall be dropped on the equipment surface which is pickled and passivated, it is
eligible that no redness appears.
2 The inspection of passivating film shall be carried out on the test panel which is
carried out the surface-treatment under the same conditions, dissolve 10g red prussiate of
potash into 500mL water, add 10mL concentrated sulfuric acid and 20mL concentrated
hydrochloric acid, dilute it to 1000mL and make it act as test solution, then drop it on the
washed surface, it is eligible that no deep-blue appears in 0.5 ~ 1min.
Check method: Visual check.
4.9.2 As for the austenitic stainless steel equipment, the chloride ion content in flashing
water shall not be more than 25mg/L.
Check method: Check the report of chloride ion content in water.
4.9.3 The equipment degreasing quality check method and approval standard shall meet the
following requirements:
1 Direct method:
1) Wipe the in-wall and internal components for the equipment in clean and dry
white-filter paper, the Lipin shall not be on the paper.
2) In the UV-lamp whose wavelength is 320~380nm, the hyacinthine fluorescence
shall not be on the degreasing surface.
2 Indirect method:
1) When steam is used to blow and clean the degreasing, a little steam condensate
shall be filled in the vessel, and some pure camphor whose granularity is less than
1mm shall be pulled into the vessel, it is eligible that camphor keep gyrating.
2) When the organic solvent or aqua fortis is used for degreasing, the solution or
acid which has been degreased shall be took away for analyzing the oleaginous or
organic matter contents, their contents shall not be more than 0.03%.
4.9.4 The ware trace or alkali trace must not be on the aluminium equipment after the
chemical cleaning.
Check method: Visual check.
4.9.5 After the chemical cleaning is adopted for the titanium equipment, the red prussiate of
potash or (C12H3N2) solution shall be spread (or sprayed) or the filter papers which contain
aforesaid solutions shall be attached on the equipment surface, the solution or filter paper
shall not be discolored.
4.9.6 The interior shall be unscrambled before the equipment is seal, the adhesive materials
and sundries shall not be on it.
5 On-site Welding for Equipment
5.1 General Requirements
5.1.1 Not only the requirements stipulated in Article 3.5 of this code, but also the following
materials shall be equipped with:
1 Report of welding procedure qualification and guidebook of welding work.
2 Quality supporting documents of welding material.
3 Arrangement drawing of equipment.
Check method: Check the related materials.
5.1.2 The welding procedure qualification of the pressure vessel shall be implemented
according to the current relevant standard “Welding Procedure Qualification for Steel
Pressure Vessels” JB 4708, the welding procedure qualification of non-pressure vessel may
comply with the current relevant standard of the national “Code for Construction and
Acceptance of Field Equipment, Industrial Pipe Welding Engineering” GB 50236. The
welding procedure qualification of low temperature pressure vessel shall comply with the
current national standard “Steel Pressure Vessels” GB 150 and the low temperature Charpy
Impact Test (V-notch) shall be added for the welding seam and heat-affected zone.
Check method: Check the report of welding procedure qualification.
5.1.3 The designations like material code, assembling (arranging) serial number on the
assembling component shall be in accordance with the arranging drawing.
Check method: Inspect on-site according to the arranging drawing.
5.1.4 If the equipment is assembled on the foundation, the concrete foundation shall meet
the requirements of Article 4.1.1 and 4.1.6 in this code.
5.1.5 The welding rods shall be baked according to the requirements of the specifications or
welding technology documents before they are used.
Check method: Check the record of welding rods baking.
5.1.6 The spherical tank welding rods and flux-cored wires shall be re-inspected for the
diffusible hydrogen content of deposited metal according to the batch number; the diffusible
hydrogen content shall meet those specified in Table 5.1.6 after baked. The diffusible
hydrogen content test shall meet the relevant requirements of current national standard
“Methods for Determination of Diffusible Hydrogen in Deposited Metal of Covered
Electrodes” GB/T 3965.
Check method: Check the re-inspection “report of diffusible hydrogen content of
welding rods”.
Check method: Visual check.
5.3.12 The assembly of support and skirt support shall meet the following requirements:
1 The permissible variation of planeness of the pedestal which arrived in section is
3mm after welded; the permissible variation of center distance of anchor bolt holes at the
interface is ±2mm; the permissible variation of center circle diameter of anchor bolt hole is
±2mm.
2 The permissible variation of pedestal loop, skirt support and equipment noumenon
axial line is 5mm.
3 At the connection section of support, skirt support and equipment noumenon, the
opening shall be set on the support and skirt support if there is any splicing weld.
Check method: Inspect on-site with steel rule according to the arranging drawing.
5.3.13 The difference between the maximal shell internal diameter and minimal shell
internal diameter shall be less than 3% of the design internal diameter of spherical tank and
not larger than 50mm after the spherical tank is assembled. The difference between the
maximal shell internal diameter and minimal shell internal diameter shall be in accordance
with the following requirements after other equipment are assembled:
1 The difference of the maximal shell internal diameter and the minimal shell internal
diameter on a same cross section shall not be larger than 1% of the internal diameter of this
cross section and not larger than 25mm.
2 When the checked cross section is located at the one time open pore internal diameter
scale of the open pore centre, the difference of the maximal internal diameter and the minimal
internal diameter on the cross section shall not be larger than the sum of 1% of the cross
section internal diameter and 2% of the open pore internal diameter, and not larger than
25mm.
Check method: Measure with pull-wire or check the inspection report.
5.4 Welding
5.4.1 When one of the following situations appears in the welding environment, the welding
work must not be carried out if no effective protection measure is adopted:
1 In the situation of welding rod arc welding, the wind speed is larger than 8m/s.
2 In the situation of shielded arc welding, the wind speed is larger than 2m/s.
3 The relative humidity is larger than 90%.
4 Raining and snowing environment
5 The welding temperature is lower than－20℃.
Check method: Measure on-site with anemoscope, electron temperature meter, hygrometer
Check method: Visual check.
5.4.7 The workpieces like lifting eye, fixture that welded with equipment shell shall meet
the following requirements:
1 The material shall be same to the equipment shell or in the same classification.
2 Adopt regular welding technology or qualified welding technology.
3 When the fillet weld of the junction panel and equipment shell is continuous weld,
the ventholes shall be put apart at the position where rainwater is difficult to flow in.
4 When the equipment shell weld requires preheat, the preheat shall be carried out for
the workpiece weld, the upper value shall be adopted for the preheating temperature, and the
preheat range should not be less than 150mm of workpiece periphery.
5 After the heat treatment and withstand voltage test is carried out, the workpiece shall
not be welded on the equipment noumenon.
6 The base material shall not be damaged when dismantling, the residual traces shall be
burnished and trimmed after dismantling, the depth of trimming shall not be larger than 5% of
the steel thickness of the section, and not larger than 2mm, or it shall be welded up.
Check method: Check the related data.
5.4.8 The welding repair shall meet the following requirements:
1 The welding repair shall be carried out according to the qualified welding technology.
2 The trimmed depth of flaw on the weld surface shall not be larger than 5% of steel
thickness of this section and not larger than 2mm, and it shall be...