液化气钢瓶检验站质量保证册(共106页).doc

精选优质文档-倾情为你奉上 目 录颁布令·································································4站长等任命书···························································5第一部分总则···························································6一、公司基本情况·······················································6二、钢瓶检测质量保证手册编制法律、法规和相关标准依据···················7三、编制目的···························································7四、钢瓶检验站主要职责·················································8五、钢瓶检验站质量目标、质量方针·······································8六、行政组织机构图·····················································9七、质量管理责任人员组成图·············································10八、质量管理职能分配表及人员一览表·····································11九、钢瓶检测站工作人一览表·············································13十、钢检站检测仪器工具一览表···········································14十一、钢检站设备一览表·················································15十一 检验质量控制系统·················································16十二、钢瓶检测站质量控制一览图·········································19第二部分钢瓶检测站安全操作规程·········································251、待检钢瓶抽残操作规程················································262、钢瓶瓶阀装卸瓶阀机操作规程··········································263、超声波测厚仪操作规程················································274、钢瓶水压试验机操作规程··············································275、焚烧炉操作规程······················································286、抛丸除锈机操作规程··················································297、静电喷涂机、固化烘箱操作规程········································298、钢瓶气密试验机操作规程··············································299、空气压缩机操作规程··················································3010、真空泵操作规程·····················································3111、可燃气体检测操作规程···············································3112、液化石油气钢瓶瓶阀校验台操作规程···································3113、液化石油气钢瓶印字机操作规程·······································3214、钻床安全操作规程···················································3215、砂轮机安全操作规程·················································3316钢瓶内残气处理操作规程···············································3317、气瓶外观检验操作规程···············································3418、气瓶附件检修及安装操作规程·········································3419、气瓶除锈、喷漆、标记操作规程·······································35第三部分 安全管理制度·················································36（一）、公司经理岗位责任制··············································39（二）、生产副经理岗位责任制············································39（三）、设备副经理岗位责任制············································40（四）、站长岗位责任制··················································40（五）质保工程师（质量技术负责人）岗位责任制···························41（六）安全员岗位责任制·················································42（七）钢瓶检测员岗位责任制·············································42（八）钢瓶检测班长岗位责任制···········································43（九）运行工（抽残工）岗位责任制·······································43（十）门卫岗位责任制···················································44（十一）设备管理（压力容器管理员）岗位责任制···························44（十二）资料管理员岗位责任制···········································44（十三）钢瓶检验收发员（营业员）岗位责任制·····························45第四部分管理制度·······················································46一、出入气库须知·······················································46二、生产区八大禁令·····················································46三、安全培训教育考核制度···············································47四、安全教育的计划管理制度·············································47五、安全培训教育对象管理制度···········································47六、安全培训教育内容···················································47七、安全培训教育要求···················································48八、日常安全教育管理制度···············································49九、安全检查和隐患整改管理制度·········································49十、安全生产值班制度···················································52十一、安全作业管理制度·················································53十二、压力容器、压力管道安全使用管理制度·······························54十三、新购气瓶安全管理制度·············································55十四、接收待检测钢瓶检查登记管理制度···································57十五、检验合格钢瓶储存、发放管理制度···································57十六、气瓶报废、不合格气瓶处理制度·····································58十七、技术资料档案管理制度·············································59十八、用户信息反馈制度·················································60十九、用户宣传教育及服务制度···········································62二十、设备安全维修保养管理制度·········································63二十一、计量器具与仪器仪表管理制度·····································64二十二、特种作业人员管理制度···········································65二十三、巡回检查制度···················································66二十四、文明生产制度···················································66二十五、消防器材管理制度···············································67二十六、接受特种设备安全监察管理制度···································68二十七、临时用电安全管理制度···········································69二十八、用火作业安全管理制度···········································71二十九、事故管理制度···················································76三十、检验报告的填写和审核制度·········································77三十一检验质量考评制度·················································78三十二、检验工作安全管理制度···········································79三十三、外购配件验收和保管制度·········································79三十四、检验过程关键点质量控制制度····································80第四部分记录表卡······················································81液化石油气钢瓶定期检验报告············································86液化石油气瓶定期检验合格证············································88气瓶判废通知书························································90检验质量情况信息反馈表················································92第五部分 钢瓶检测站事故处理应急预案··································93一、制定钢瓶检测站事故处理应急预案的目的及意义····················93二、液化石油气的特性··················································93液化石油气的危险、危害性··············································93三、压力容器具有物理性爆炸的危险性，从而引起人员伤亡和财产损失········94四、应急预案响应、启动程序············································95五、钢瓶检测站内应急器材··············································95六、周边环境慨况······················································96七、钢瓶检测站可能发生的事故及其危险、危害程度（范围）预测············96八、应急组织机构、部门职责、人员情况··································97（一）应急救援组织机构················································97（二）、应急组织机构图·················································98（三）、各部门及岗位人员职责···········································98第六部分 应急处理人员一览表·········································100(一) 应急处理现场管理················································101(二) 应急处理措施（方法）·············································1021、钢瓶阀芯泄漏的处理方法············································1032待检钢瓶瓶体泄漏堵漏的方法有······································1033待检钢瓶角阀发生泄漏液化石油气泄漏已造成着火时的处理方法··········1034、待检钢瓶泄漏着火处理方法··········································1035待检钢瓶倒残过程中发生泄漏时的处理方法····························1036待检钢瓶倒残过程中发生泄漏着火时的处理方法························1047焚烧炉管线及阀门泄漏着火··········································1048钢瓶水压试验发生爆炸的处理方法····································1049、焚烧炉、烘烤炉发生灼伤事故的处理方法······························10410、气密试验中发生钢瓶爆炸事故的处理方法·····························107营业执照·····························································108组织机构代码证·······················································109燃气经营许可证·······················································110颁 布 令 为了确保液化石油气钢瓶检验质量和昆质监局通2011212号文件要求，结合本公司中国石化集团西南石油局云南石油天然气销售公司大石坝钢检站气瓶检验的特点，根据压力容器安全技术监察规程、特种设备安全监察条例、气瓶安全监察规程、GB83341999液化石油气钢瓶定期检验与评定、GB121351999气瓶定期检验站技术条件、GB58421996液化石油气钢瓶等国家法规标准对气瓶检验单位要求，我站认真修订了2012版液化石油气钢瓶检验质量保证手册，现予颁布。 本手册是本公司钢检站质量管理体系的法规性文件，是指导本钢检站建立并实施质量管理体系的纲领和行动准则。全站职工必须认真学习、遵照执行。 本手册自2012年1月15日起开始执行。 经 理： 二O一二年 一月八日第一部分 总 则一、公司基本情况：二、钢瓶检测质量保证手册编制法律、法规和相关标准依据依据国家有关特种设备的法律、法规和相关标准如下：安全生产法、压力容器安全技术监察规程、特种设备安全监察条例、气瓶安全技术监察规程气瓶安全技术监察规定GB83341999液化石油气钢瓶定期检验与评定GB121351999气瓶定期检验站技术条件GB168041997气瓶警示标签GB510019994钢质焊接气瓶GB7144-1999气瓶颜色标志GB7512-1998液化石油气瓶阀GB/T9251-1997气瓶水压试验方法GB12137-1989气瓶气密试验方法GB10878-1999气瓶螺纹丝锥GB5842-1996液化石油气钢瓶三、编制目的四、钢瓶检验站主要职责（1）对气瓶进行定期检验并出具检验报告；（2对气瓶附件进行维修或更换；（3）对气瓶表面的涂敷；（4）对报废气瓶进行破坏性处理； 五、钢瓶检验站质量目标、质量方针受检液化石油气钢瓶98无漏检、错检。检验结论准确无误，正确性达98。受检单位0.5%投诉。关键检验检测设备的完好率达95。实现：凡经本公司中国石化集团西南石油局云南石油天然气销售公司大石坝钢检站检验过的液化石油气钢瓶，在检验有效期内决不出现因检验质量失控而导致的安全责任事故。质量方针是：品质优良、服务为本，顾客至上、安全无忧。六、行政组织机构图七、质量管理责任人员组成图 八、质量管理职能分配表及人员一览表 经理管理者代表质量技术负责人站长检验责任工程师检验人员4质量管理体系文件要求4.2质量手册4.3文件控制4.4质量记录的控制5管理职责5.1管理承诺5.2关注焦点5.3质量方针5.4策划5.5职责,权限与沟通5.6管理评审6资源管理6.1资源的提供6.2人力资源6.3基础设施6.4工作环境7检验服务实现7.1实现过程的策划7.2与受检单位有关的过程7.3采购7.4检验服务提供7.5检验报告7.6保密7.7检验工作安全8监控、分析和改进8.1策划8.2监控8.3不合格控制8.4数据分析8.5改进9抱怨和申诉10接受特种设备安全监察机构的监督11合作及信息交流注：领导责任；负责实施；o配合实施。九、钢瓶检测站工作人一览表十、钢检站检测仪器工具一览表十一、钢检站设备一览表十二 检验质量控制系统1 总则1.1为了加强液化石油气钢瓶(以下简称钢瓶)的定期检验工作，统一检验程序及内容，提高检验工作质量，根据特种设备安全监察条例、气瓶安全监察规程及有关规程、国家标准、规范的规定，特制定本规范。12本规范适用于正常环境温度在-4060范围内使用的，试验压力为3.2MPa，公称容积为1.2L，4.7L，12L，23.5L，35.5L，118L可重复充装的液化石油气钢瓶。2 检验工作依据A、气瓶安全监察规程B、GB5842液化石油气钢瓶C、GB15380小容积液化石油气钢瓶D、GB8334液化石油气钢瓶定期检验与评定E、GBT925l气瓶水压试验方法F、GBT12137气瓶气密性试验方法G、GB7144气瓶颜色标记3 检验人员资格和职、责、权3.1检验人员必须持有省级以上(含省级)质量技术监督部门特种设备安全监察机构颁发的GG或RS或QP检验资格证书，且在有效期内。3.2检验人员的职、责、权见检验人员岗位责任制。4 检验前的准备4.1钢瓶使用单位应做的准备：4.1.1集中到期钢瓶，以及库存或停用时间超过一个检验周期的钢瓶4.1.2集中受到严重腐蚀、损伤以及其他可能影响安全使用的缺陷的钢瓶4.1.3提供对检验工作有参考价值的技术资料(如钢瓶的原始资料、检验资料等)4.1.4将应检钢瓶送至气瓶检验站4.2检验员应做的准备工作4.2.1逐只检查登记钢瓶的制造标志和检验标志，登记内容包括：制造厂名或钢瓶制造许可证编号，出厂编号，水压试验压力，公称工作压力，实际重量，实际容积，钢瓶设计壁厚，出厂日期，钢瓶材质牌号，上次检验日期。4.2.2对未经国家特种设备安全监察机构认可的厂家制造的钢瓶、制造标准不符合GB5842，GBl5380和气瓶安全监察规程规定的钢瓶，以及有关政府文件规定不准再用的钢瓶，登记后不予检验，按报废处理。4.2.3对使用期限超过15年的任何类钢瓶，登记后登记后不予检验，按报废处理。5 检验工作程序见附件一。6 检验工作内容及要求6.1检验周期对在用的YSP 0.5型、YSP一2.0型、YSP一5.0型、YSP一10.0型和YSP一15型钢瓶，“自制造日期起第一次至第三次检验的检验周期均为4年，第三次检验的有效期为3年”；对在用的YSP一50型钢瓶每3年检验一次。当钢瓶受到严重腐蚀、损伤，以及其他可能影响安全使用的缺陷时，应提前进行检验。库存或停用时间超过一个检验周期的钢瓶，启用前应进行检验。6.2检验内容及要求见附件二液化石油气钢瓶定期检验工艺表。7检验文件的出具和管理71液化石油气钢瓶定期检验记录(见附件三)72液化石油气钢瓶定期检验合格证(见附件四)73液化石油气钢瓶判废通知书(见附件五)8定期检验工作质量问题处理检验中发现的质量问题，应作详细记录，处理按质量保证手册规定执行9 检验安全注意事项见质量保证手册第二、三部分的规定。10 附则l0.1本规范若与国家及上级特种设备安全监察机构有关法规、安全监察文件不符时，应以上述法规、文件、规定为准。10.2特种设备安全监察机构对检验单位的工作质量进行监督。十三、钢瓶检测站质量控制一览图附件一液化石油气钢瓶定期检验质量控制一览表序号检验质量控制点检验内容检验要求及规定检验要求检验方式控制复核人控制见证备注1外观初检与评定逐只目测检查易发现和评定的外观缺陷存在下列情况之一的受检瓶报废1、无任何制造标志的钢瓶；2、有纵向焊缝（YSP-50型钢瓶除外）或螺旋焊缝的钢瓶；3、耳片护罩脱落或其焊缝断裂以及主焊缝出现裂纹的钢瓶；4、因底座脱落、变形、腐蚀、破裂、磨损以及其他缺陷影响直立的钢瓶；5、局部或全面遭受火焰或电弧烧伤；6、瓶体倾斜、变形或封头直边存在纵向皱褶深度大于钢瓶外径0.25%；7、底座支承面与瓶底中心的间距小于下列尺寸；YSP-0.5、YSP-2.0、YSP-5.0型：4mmYSP-10.0和YSP-15型：6mmYSP-50型：8mm目测工具尺2残气浓度检测逐只检测残气浓度残气浓度应低于0.4%（体积），不合格的应重新进行置换处理现场检验3外观复检与评定逐只进行外观复检与评定1、阀座出现裂纹或陷入瓶体，报废；2、螺纹不允许存在裂纹及裂纹性缺陷，但在有效螺纹中允许有不超过3牙的缺口，且缺口长度不超过圆周的1/6，缺口深度不超过牙高的1/3；3、螺纹出现轻度腐蚀、磨损或其他损伤，可用丝锥修复，修复后应符合GB/T8336的规定，不符合者报废；4、瓶体上不允许有裂纹、明火烧伤、电弧损伤和肉眼可见的容积变形等缺陷；5、瓶体磕伤、划伤、凹坑处的剩余壁厚小于设计壁厚的90%应报废；6、瓶体凹陷深度超过10mm或大于凹坑短径的1/10，应报废；7、深度小于6mm的凹坑内磕伤或划伤深度0.4mm以及深度6mm的凹坑内存在磕伤或划伤时应报废；8、瓶体上孤立的点腐蚀的处的剩余壁厚现场检验序号检验质量控制点检验内容检验要求及规定检验要求检验方式控制复核人控制见证备注设计壁厚的2/3，线腐蚀和面腐蚀处的剩余壁厚设计壁厚90%，应报废；9、焊缝及热影响区不允许存在裂纹、气孔、弧坑、夹渣、未熔合等缺陷；10、主体焊缝或部件焊缝在瓶体一侧不允许存在咬边，焊缝表面不允许存在凹陷或不规则突变，主焊缝及其两边50mm范围内不允许有深度大于0.5的划伤或深度大于6mm的凹陷，YSP-50型钢瓶的纵焊缝与环焊缝交接处的外观质量应重点检查。11、焊缝超高、焊缝两侧飞溅物或其他超高缺陷可进行修磨，圆滑过度到母材；12、对焊缝缺陷的类型和严重性有疑问时，应采用X射线探伤方法复验，其探伤率应小于20%，按JB4730评定，III级合格。4壁厚测定钢瓶必须逐只进行壁厚测定，测厚仪的误应不大于±0.1mm1、测厚点应在上下封头圆弧过度区内各选择一点，筒体部分应选择在距焊缝两侧50mm处各一点；2、对腐蚀严重的钢瓶应在上下封头圆弧过度区各选择两点，筒体部分应选择三点；3、对YSP-50型钢瓶筒体下部和下封头圆弧过度区内应增测2点；4、经测定确认剩余壁厚设计壁厚90%的钢瓶应报废。现场检验5容积测定钢瓶必须逐只进行容积测定1、容积测定用的衡器的校验期不得超过3个月，其最大称量值应为常称重量的1.53倍；2、容积测定采用水容测定法，将经过称重的空瓶注满清水，静置24小时后，称出瓶与水的总局重量，得出瓶内容纳的水重，再乘以称重时瓶内水温下的每千克水的体积数得出该瓶的实际容积值；3、实际容积标准规定值的钢瓶应报废。现场测定序号检验质量控制点检验内容检验要求及规定检验要求检验方式控制复核人控制见证备注6水压试验钢瓶必须逐只进行水压试验，试验设施和安全措施应符合GB/T93511、水压试验压力为3.2MPa，保压时间不得少于1；2、试验过程中不允许出现渗漏、明显变形或保压期间压力下降的情况。7瓶阀检验瓶阀应逐只解体清洗、检查，更换损坏的部件1、阀体和其他部件不得有严重形，螺纹不得有严重损伤，保证开闭自如不泄漏；2、更换瓶阀或密封材料时，必须符合GB7512的规定；3、经检验，清洗和更换零部件的瓶阀组装后，逐只进行关闭状态、启闭过程和全开启状态的气密性试验，试验压力为2.MPa，保压时间不少于1min，不允许有泄漏；4、瓶阀应装配牢固并保证其与阀座连接的有效螺纹牙数和密封性能，装配后其外露螺纹数应不少于12牙。8气密性试验钢瓶必须逐只进行气密性试验；试验瓶必须是外观复检合格的钢瓶1、以空气为介质进行试验的钢瓶，试验前必须再次逐只测定瓶内残留物释放的燃气浓置换处理，合格后才能用空气进行试验；2、钢瓶的气密性试验采用侵水试验，其充气装饰置、试验水槽、试验条件和方法必须符合CG/T12137规定，3、气密性试验压力为2.1MPa，保压时间不得少于1min，保压过程中不允许泄漏、变形、压力表不允许有回降；4、因瓶阀装配不当产生泄漏的钢瓶，允许重新装配后再进行试验。9喷漆喷字按GB7144规定对检验合格的钢瓶喷漆喷字1、色泽为银灰色，均匀喷涂，漆膜光亮均匀，不允许有气包、流痕、龟裂；2、喷涂液化石油气字样，红色，字样高度为6080伤宋体；3、根据用户要求，可在瓶体背面喷其他标记。10检验标志每只检验合格的钢瓶均应装检验标志1、检验标志应有检验单位代号，本次或下次检验日期等内容；2、套于瓶阀锥形尾部上检验标志环；3、应在底盘钻直径为5检验标志圆现场检验序号检验质量控制点检验内容检验要求及规定检验要求检验方式控制复核人控制见证备注孔，第一次检验钻一个孔，第二次检验钻二个孔，第三次检验钻三个孔11抽真空逐只钢瓶进行抽真空真空度要求达到-0.075MPa现场检验12不合格钢瓶处理对检验不合格的钢瓶进行破坏性处理1、对报废气瓶进行压扁或锯切销毁；2、填写钢瓶判废通知书通知钢瓶产板注：凡经我站检验合格出厂的5KG、15KG钢瓶，在钢瓶角阀口处，必须喷涂安全标识即“提示：用气结束时请关闭角阀”第二部分 钢瓶检测站安全操作规程1、待检钢瓶抽残操作规程1、检查充装枪、阀门、管道是否完好、可靠，有无泄漏。2、检查残液罐、压缩机是否正常，压力表是否在有效期且准确。3、检查压差，当压差大于0.2MPa时开始倒残液。4、检查气相阀、残液相阀是否在正确位置。5、倒残液时按正压法操作并按下列顺序进行：关闭残液阀开启瓶阀开启枪阀，当听不到流速声时：关闭气阀开启残液阀，当残液倒空时：关闭枪阀关闭瓶阀关闭残液回收阀。残液一次不能完全回收完的，按上述顺序反复操作，直至倒空为止。6、倒残完毕应关闭所有阀门。7、做好日常保养，保持作业场地的清洁工作。8、熟悉操作、会保养维修、会排出故障9、发生事故立即按钢瓶着火预案程序处理。2、钢瓶瓶阀装卸瓶阀机操作规程1、正确穿戴劳保用品，检查齿轮箱内机油油面是否满足使用规定要求，检查电源、按钮开关是否正常。2、检查待卸钢瓶瓶体内有无残液及残气，确认无安全隐患。3、将钢瓶摆放至夹紧装置内，并操作气动开关将钢瓶夹紧。4、正确摆放瓶阀装卸机瓶阀卡钳，并选择正确旋转方向开始拆卸角阀。5、将卸完角阀的钢瓶整齐摆放，且收集整理好相关角阀，待转入下工序。6、工作结束，关闭相关电、气阀门，清洁工作场地并做好相关记录。3、超声波测厚仪操作规程。1、检查电池容量，检查电池极性是否正确，按实测壁厚需要选择探头，检查测厚仪是否准确、灵敏、可靠。2、用试块反复校正声速和起点，校正时按仪器操作说明书进行。3、清理被测面，测量时探头与被测面耦合良好，正确记录相关测量数据。4、严格按照国家标准液化石油气钢瓶定期检验与评定（GB8334-1999）和本站质保手册的规定逐只对受检钢瓶进行壁厚测定。4、使用完毕时擦试干净仪器。5、严禁敲击、碰撞探头。6、检测要认真，结论要正确，并认真做好测厚记录。4、钢瓶水压试验操作规程1、正确穿戴劳保用品。2、将被测试的钢瓶摆放至待测试点，并把相关测试装置放入钢瓶内，缓慢将气缸压紧至钢瓶阀座上，操作水泵给钢瓶注水至满。3、操作试压泵给钢瓶加压，当加压到21MPa时检查有无泄漏。4、继续加压至32Mpa并保压一分钟，观查压力表变化严密注视瓶体有无泄漏和变