Some standard content:
Chemical Industry Standard of the People's Republic of China
HG2599-94
Technical Conditions for Liquid Ammonia Tank Trucks
Published on April 8, 1994
Ministry of Chemical Industry of the People's Republic of China
Implementation on October 1, 1994
:comChemical Industry Standard of the People's Republic of China
Technical Conditions for Liquid Ammonia Tank Trucks
1 Subject Content and Applicable Scope
This standard specifies the technical requirements, test methods and inspection rules for liquid ammonia tank trucks. HG 259994
This standard is applicable to fixed tank trucks (hereinafter referred to as tank trucks) with a design pressure not exceeding 2.2MPa and a design temperature of 50℃ for transporting liquids. Other types of tank trucks may also be used for reference. 2 Reference Standards
GB 150
GB 190
GB 1300
GB 1334
GB1495
GB1589
GB1804
GB3323
GB3842
GB4785
GB5117
GB5118
GB 6654
GB 7258
GB 8163
Steel pressure vessels
Marking of dangerous goods packaging
Steel wire for welding
Road test methods for trucks and off-road vehiclesPermissible noise of motor vehicles
External dimensions of vehicles
Tolerances and fitsLimit deviations of dimensions not indicated with tolerancesRadiography and quality classification of steel fusion welded butt jointsEmission efficiency standards for gasoline vehicles
Quantity, position and color of external lighting and signal equipment for vehicles and trailersCarbon steel welding rods
Low-alloy steel welding rods
Flux for submerged arc welding of carbon steel
Carbon steel and low-alloy steel plates for pressure vesselsTechnical conditions for safe operation of motor vehicles
Seamless steel pipes for conveying fluids
GB 11567
JB1152bZxz.net
JB1164
JB2536
IB3689
JB4708
JB3965
Automobile underbody protection
Technical conditions for pressure vessel forgings
Ultrasonic testing of butt welds of boilers and pressure vesselsEqual length studs for pressure vessel flanges
Painting, packaging and transportation of pressure vessels
Braking systems of trucks and busesRoad test methodWelding procedure assessment for steel pressure vessels
Magnetic particle testing for steel pressure vessels
JB/Z 111
ZBT 50001
ZBT 50002
ZBT50003
Automobile paint coating
Special purpose vehicle finalization test procedure
Special purpose vehicle product quality periodic inspection test procedureSpecial purpose vehicle road test method
Approved by the Ministry of Chemical Industry of the People's Republic of China on April 8, 1994ww.bzsoso:com1994-10-01implemented
HG5012 Convex and concave flat welding flange
HG2599-94
HG5-1587 Spring-type safety valve for liquefied petroleum gas tanker HG5-1588 Emergency shut-off valve for liquefied petroleum gas JT3130 Rules for the transport of dangerous goods by automobile
3 Requirements for complete vehicles
3.1 In addition to being designed, manufactured, inspected and accepted in accordance with the product drawings approved by this standard and the prescribed procedures, tankers shall also comply with the provisions of GH7258 and JT3130.
3.2 The chassis of the modified automobile must be a certified product and have a product certificate from the manufacturer. 3.3 The safety devices and accessories required for the modified tanker must have a product quality certificate; after the tank body is manufactured, it shall be tested with a test force of 1.5 times and 1.0 times the design pressure of the tank body, and the water pressure strength test and air tightness test shall be carried out on the tank body to ensure that they are qualified. 3.4 The basic performance and main technical parameters of the tank truck after installation shall meet the requirements of the original vehicle chassis; under no-load and static conditions, the maximum roll stability angle shall not be less than 35”
3.5 The overall dimensions of the vehicle shall comply with the provisions of GB1589; the rear overhang of the vehicle shall not exceed 65% of the wheelbase, and the maximum shall not exceed 3.5m. 3.6 The noise and pollution emission standards of the tank truck shall comply with the provisions of GB1495 and GB3842. 3.7 The connection between the tank truck and the chassis shall be firm and reliable. Under no circumstances shall the tank body move longitudinally or transversely relative to the chassis. 3.8 The various safety devices and accessories installed on the vehicle according to the design drawings shall be complete, firmly installed, easy to operate, and reliable in operation. 3.9
The appearance of the tank should be neat, all metal components should be rust-proofed and painted, and the paint layer of the tank body should be uniform. Color The markings are clear and the fonts are neat. There are no defects such as wrinkles, bubbles, paint peeling and flow marks on the surface of the tank. 4 Tank design
4.1 Material selection
4.1.1 The quality of materials used to manufacture the tank body shall comply with the relevant national standards and industry standards of my country. 4.1.2 Plates and pipes for manufacturing tank bodies and pressure-bearing components. The materials and forgings shall refer to the provisions of GB150. The steel plate for manufacturing the tank body shall be 16MnR steel plate for pressure vessels with a service point standard value lower than 400MPa: carbon steel or low-alloy steel forgings for manufacturing manholes shall be selected in accordance with the provisions of JB755; the forging grade shall not be lower than Grade II, 4.1.3 Welding materials shall comply with the provisions of GB1300, GB5117, GB5118 and GB5293, 4.1.4 When using foreign materials, foreign pressure vessels should be selected. The materials allowed for use in the equipment specifications shall comply with the provisions of the corresponding specifications of the country and shall comply with the provisions of Appendix A of GB150. 4.1.5 The protective hose connected to the tank body shall be an oil-resistant rubber tube with a pressure resistance of not less than 6MPa. 4.1.6 All pipes, internal parts and valves of the tank body in contact with the medium are not allowed to be made of copper. 4.2 Tank structure
4.2.1 The tank body shall be a steel welded structure, and there shall be no insulation layer on the outer surface of the tank body. 4.2.2 A manhole with a diameter of not less than 400mm must be set on the tank body, and at least one liquid phase pipe and one gas phase pipe shall be provided. The valves on the liquid phase pipe and the gas phase pipe shall have overflow valves and relief valves for discharging residual liquid and residual gas. 4.2.3 A wave-breaking plate shall be installed inside the tank body in a direction perpendicular to the axis of the tank body. The separation volume of the wave-breaking plate shall not be greater than 3m. The wave-breaking plate and The connection of the tank body should have sufficient strength and will not be damaged by the impact of the medium in the tank body. 4.2.4 The main welds of the tank body must adopt a double-sided welding structure, and the fillet welds at the manhole and pipe opening should also adopt an easy-to-penetrate structure. 4.3 Design pressure and filling volume
4.3.1 The design pressure of the tank body shall not be less than 2.2MPa. 4.3.2 The maximum filling weight allowed by the tank truck shall not exceed the value calculated by the following formula: .2
HG2599-94
Where: W-the maximum filling weight allowed by the tank truck kg; V--the actual volume of the tank body L;? Weight filling coefficient kg/L, take 0.52.4.4 Strength calculation of the body
4.4.1 The strength calculation of the body and the design of the flat, opening and flange can be carried out according to the provisions of GB150. However, its safety factor should be taken as n5>3; the corrosion margin of the tank body shall not be less than 2mm. 4.4.2 The minimum pound thickness of the tank body shall not be less than 6mm4.4.3 The tank body shall also be subjected to stability verification according to the provisions of Article 4 of GB150, and subjected to an external pressure of 0.1MPa.4.5 The measured minimum buoyancy allowed for delivery shall be marked on the general drawing of the tank body.5 Tank body manufacturing
5.1 Material inspection and marking
5.1.1 The materials of the tank body and light-receiving parts of the tank car shall comply with the provisions of the relevant standards and product drawings, and have a quality certificate.
5.1.2 Before feeding, the materials of the tank body and main pressure-bearing components shall be re-tested for chemical composition and room temperature mechanical properties according to the provisions of this standard and the requirements of the material standard, and the surface quality of the steel plate shall be inspected sheet by sheet.5.1.3 After the materials are unloaded, the manufacturer shall promptly carry out material marking. 5.2 The classification of welds in the pressure-bearing part of the booth shall be in accordance with the provisions of GB150. 5.3 Hot and cold processing or forming
5.3.1 The surface of the groove must be smooth
a. There shall be no defects such as cracks, delamination, slag inclusions, etc. on the surface of the groove; b. Before welding, the oxides, oil stains, molten porcelain and other harmful substances on the surface of the groove shall be cleaned. The range of cleaning (measured by the distance from the edge of the groove) shall not be less than 20mm. 5.3.2 Head
5.3.2.1. The head plate is integrally stamped or spun. 5.3.2.2 The head is allowed to be butt-welded by two or more steel plates. 5.3.2.3 The minimum thickness of the formed head shall not be less than the nominal thickness 5, minus the negative deviation of the steel plate thickness 5.3.2.4 The inner surface shape deviation of the formed head shall be checked with an inner sample with a chord length not less than 3/4 of the designed inner diameter D, of the head (see Figure 1). The maximum gap shall not be greater than 1.25% of the designed inner diameter D, of the head. The longitudinal wrinkle depth of the straight edge part shall not be greater than 1.5mm. The head
section and the tank
section shall be cold rolled.
3D,/ 4
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The misalignment b of the A and B type welds of the key body (see Figure 2) shall comply with the provisions of Table 1. The nominal thickness at the opposite position of Table 1
.
Amount of misalignment according to weld type
The angle E formed by welding in the circumferential direction shall be checked with an inner or outer sample with a chord length equal to 1/6 of the designed inner diameter D and not less than 300mm (see Figure 3). The E value shall not be greater than (0.15, +2)mm (the nominal float of the body) and shall not be greater than 5mm. The angle 5 formed by the two welds in the axial direction (Figure 4) shall be checked with an inspection ruler with a length of not less than 300mm. Its value shall not be greater than (0.15, -2)mm: F shall not be greater than 5mm1.
1/6D, and not less than 30G
1/6D; ear not less than 300
5.3.3.4 During assembly, the length of the section shall not be less than 300mm, the distance between the Class A welds of adjacent cylinder sections or the distance between the end point of the Class A weld of the head and the Class A weld of the adjacent section shall be greater than 3 times the nominal thickness 6., and not less than 100mm, 5.3.3.5 The flange surface shall not be perpendicular to the main axis center line of the connection or the body. When installing the connection flange, the flange surface shall be horizontal or vertical (special requirements shall be specified in the drawings), and the deviation shall not exceed 1% of the flange outer diameter (when the flange outer diameter is less than 100mm, it shall be calculated as 100mm), and shall not exceed 3mm
The bolt holes of the flange shall be arranged in the middle of the main axis or plumb line of the tank body (see Figure 5). When there are special requirements, they should be indicated in the drawings. HG
2599—94
5.3.3.6 The allowable error of the tank body straightness should be less than or equal to 2/1000 of the cylinder length H, and not more than 20mm. Note: The straightness inspection of the tank body is carried out on the horizontal and vertical planes passing through the center line, that is, along the circumference of 0°, 90°, 180°, and 270°, and a 0.5mm group steel wire is pulled to measure. The distance between the measuring position and the Class A weld should be not less than 100mm. 5.3.3.7 The distance between the weld seam between the inner parts and the tank body and the weld seam between the cylinder sections and the weld seam between the cylinder body and the head should be not less than 50mm
5.3.3.8 All welds covered by the reinforcement ring, support Liao, internal parts, etc. on the tank body should be polished to be flush with the parent material. 5.3.3.9 After the tank body is assembled, check the tank body's clearance according to the following requirements: a. The difference between the maximum inner diameter and the minimum inner diameter on the same section of the tank body, e, should not be greater than 1% of the designed inner diameter D, of the surface, and should not be greater than 25mm (see Figure 6); b. When the section to be inspected is located within the range of one times the inner diameter of the opening from the center of the opening, the difference between the maximum inner diameter and the minimum inner diameter of the section, e, should not be greater than the sum of 1% of the designed inner diameter D, of the section and 2% of the inner diameter of the opening, and should not be greater than 25m. 5.3.3.10 Mechanical damage to the steel plate surface should be avoided during manufacturing. Severe sharp scratches should be ground, and the slope of the repair should be at least 3:1.
The depth of the ground area shall not exceed 5% of the nominal thickness 5, and shall not be greater than 2mm. When the above requirements are exceeded, repair welding is allowed. 5.3.4 Manholes and flanges
5.3.4.1 Pipe flanges and manhole flanges shall be processed according to the requirements of the corresponding standards. Figure 6
5.3.4.2 Bolts, studs and nuts shall be selected and manufactured according to the corresponding standards according to the requirements of the drawings. 5.3.4.3 Manhole flanges and studs shall be in accordance with the provisions of JB1164. 5.3.5 The limit deviations of the unindicated tolerance dimensions of machined surfaces and non-machined surfaces shall be in accordance with the J14 and Js16 grades of accuracy specified in GB1804.
5.4 Tank welding
5.4.1 The welding of the pressure-bearing part of the tank must be carried out by welders holding valid welder certificates of the corresponding category issued by the labor department. 5.4.2 Preparation before welding and welding environment
HG2599--94
5.4.2.1 The storage of welding rods, flux and other welding materials should be kept dry, and the relative humidity should not be greater than 60%. 5.4.22 When any of the following conditions occur in the welding environment and there are no effective protective measures, welding is prohibited: a. The wind speed is greater than 10m/s during manual welding; h. The wind speed is greater than 2m/ss during gas shielded welding; c. The relative humidity is greater than 90%; d. Dew environment. 5.4.2.3 When the temperature of the weldment is lower than 0°C, it should be preheated to about 15°C within 100mm of the welding start point. 5.4.3 Welding process
5.4.3.1 For any steel type welded for the first time or welding materials and welding methods used for the first time; and for any change in any basic factor or additional factor in the welding process that has been qualified, the welding process should be qualified in accordance with the provisions of JB4708 before welding. 5.4.3.2 The welding process specification of the whole body should be formulated according to the technical requirements of the drawings and the qualified welding process. 5.4.3.3 The welder must strictly abide by the welding process specification to weld, and keep welding records. After welding, the welder code is stamped on the specified position near the weld.
5.4.3.4 The welding process qualification report, welding process specification, welding records and welding identification marks shall be kept for not less than 5 years. 5.4.4 The shape, size and appearance of the weld surface 5.4.4.1 The weld reinforcement of Class A and B (see Figure 7) shall be in accordance with the provisions of Table 2. Table 2
Weld depth (s,)
Weld reinforcement e (er)
Hand welding
Automatic welding
Note: Weld depth: For single-sided welding, it is the thickness of the base material; for double-sided welding, it is the depth from the midpoint of the straight edge of the mouth to the surface of the base material, calculated separately.
5.4.4.2C, D Type welds: The weld leg of C, D type welds shall be the thickness of the thinner weldment when no provisions are made in the drawings. For reinforced weld legs, when the thickness of the reinforcement ring is not less than 8mm, the weld leg shall be equal to 70% of the thickness of the reinforcement ring and shall not be less than 8mm. 5.4.4.3 The quality requirements for weld surface are as follows:
: The weld surface and heat affected zone shall be free of defects such as cracks, undercuts, pores, arc pits and slag inclusions, and shall not retain slag and spatter. b. C, D type welds shall have a smooth transition to the geometric shape of the parent material. c. The thickness of the weld surface defects or mechanical damage after grinding shall comply with the provisions of Article 5.3.3.10. 3.5 Test Plate and Test Specimen
5.5.1 Each tank car body shall be made into a product A-type weld test plate. For tank cars produced in batches, if the welding quality is stable, it is allowed to replace the unit with the batch after approval by the provincial, municipal or district labor bureau. The regulations are as follows:
HG 2599--94
a. Take no more than 15 tank trucks as a batch, and the number of random inspections of the test plates shall not be less than 2; b. If a batch cannot be completed within 6 months, at least one product test plate must be inspected within a period not exceeding 6 months. If the test results of the product test plates replaced by batches are found to be unqualified, the production of product samples shall be resumed immediately. 5.5.2 Requirements for preparing product explosion-proof test plates
5.5.2.1 The material of the test plate must be qualified and have the same brand, specification and heat treatment process as the chain body material. 3.5.2.2 The welder who welds the test plate with the weld body shall weld the tank body welded by multiple welders under the same conditions and with the same welding process as the tank body. The welder who makes the welding test plate shall be designated by the inspection department of the manufacturing unit. 5.5.2.3 The test plate must be welded at the extension of the A weld of the cylinder section and the cylinder section at the same time. 5.5.2.4 The test plate shall be subjected to reverse post-weld heat treatment together with the tank body. 5.5.2.5 The dimensions of the test plate shall comply with the provisions of Appendix G of GB150. 5.5.3 The product welding test plate shall be inspected and evaluated in accordance with Appendix G of GB150. 5.6 Non-destructive testing of welds
5.6.1 The non-destructive testing of welded joints of the cylinder, head and main pressure-bearing components shall be carried out after the shape, size and appearance inspection of the body are qualified.
5.6.2 The non-destructive testing of welds must be carried out by personnel holding a valid non-destructive testing personnel qualification certificate for the corresponding method issued by the labor department.
5.6.3 Inspection scope of non-destructive testing
5.6.3.1 Class A welds and Class B welds in the tank body shall be subjected to 100% radiographic testing. If there are any unacceptable defects in the welds inspected by radiography, they shall be repaired in accordance with the provisions of Article 5.7 after the defects are eliminated, and the welds shall be re-inspected using the original inspection method until they are qualified. 5.6.3.2 Class D welds between main pressure-bearing components such as manholes, connecting pipes, flanges and shells, and Class C welds between flanges and pipes, should be subjected to 100% magnetic particle or penetrant testing. 5.6.4 Assessment Standards
5.6.4.1 Radiographic flaw detection of welds shall be carried out in accordance with GB·3323, and the quality requirements of radiography shall not be lower than AB grade, and the inspection results shall not be lower than the health grade to be qualified.
5.6.4.2 Magnetic particle flaw detection shall be carried out in accordance with JB3965, and the inspection results shall meet the requirements of Article 20 of its standard. 5.6.4.3 Penetrant flaw detection shall be carried out in accordance with Appendix H of GB150, and no cracks or delamination shall be allowed. 5.6.5 Defects found by magnetic particle flaw detection and penetrant flaw detection shall be repaired and welded in accordance with the provisions of Articles 5.3.3.10, 5.4.4.3 and 5.7, and the weld shall be re-inspected by source flaw detection method until it is qualified. 5.6.6 All original flaw detection data (including negatives and records) of the tank body shall be kept by the manufacturing unit for at least 5 years. After 5 years, it can be transferred to the user for safekeeping if needed.
5.7 Weld Repair
5.7.1 Welds found to be unqualified during tank manufacturing should be repaired, and the repair process should comply with the provisions of Article 5.4. 5.7.2 The number of times the same part of a weld is repaired should not exceed two times. For welds that are still unqualified after two repairs, if they are repaired again, each time they must be approved by the technical person in charge of the manufacturing unit, and the number of repairs, parts and repair conditions shall be recorded in the product quality certificate. 5.7.3 Weld repair should be carried out before the heat treatment of the tank. After repair, the weld should be inspected and qualified by the original flaw detection method. 5.8 Post-weld stress relief heat treatment
5.8.1 After the tank body is manufactured and inspected and qualified, it must be subjected to overall stress relief heat treatment (hereinafter referred to as heat treatment). 5.8.2 The heat treatment of the tank body shall be carried out in accordance with the heat treatment process regulations formulated in accordance with the drawings or technical documents. 5.8.3 Weld defects found after heat treatment shall be repaired in accordance with Article 5.7. The repaired weld shall be subjected to local heat treatment in accordance with Article 10.4.3 of GB150.
HG 2599-94
5.8.4 The heat treatment shall be recorded in detail on paper. The heat treatment time and temperature relationship curve record shall be kept for not less than 7 years. Safety devices and accessories
6.1 Safety valve
6.1.1 The top phase space of the tank body must be equipped with at least one internal full-opening spring-loaded safety valve. The manufacture and inspection of the safety valve shall comply with the provisions of HG5-1587.
6.1.2 The opening force of the safety valve shall comply with the relevant provisions of the Ministry of Labor on liquefied gas tank trucks. The sealing pressure of the safety valve shall not be less than 0.9 times of the opening force, the sealing force shall not be less than 0.8 times of the opening force, and the opening height shall ensure that the area is larger than the throat area.
6.2 Emergency shut-off valve
6.2.1 A set of built-in emergency shut-off valve remote control system shall be installed at the main interfaces of the liquid phase pipe and gas alarm pipe of the tank truck. The operating device should be located in a place that is easily accessible to personnel, and can be used to close the emergency shut-off valve in time in case of fire or large-scale leakage in the pipeline.
6.2.2 The manufacture and inspection of the emergency shut-off valve shall comply with the provisions of HG5-1588. 6.3 The accuracy of the pressure gauge shall not be lower than Class 1.5, and the dial scale limit value shall be 1.5 to 3.0 times the design pressure of the tank. A red mark shall be applied at the saturated vapor pressure corresponding to the medium temperature of 40°C and 50°C. 6.4 The measurement range of the thermometer shall be -40 to 60°C. C, and red marks are applied at 40℃ and 50℃. 6.5 Liquid level gauges and their measuring devices must be sensitive and reliable, and have sufficient strength and firmness. Glass plate liquid level gauges shall not be used in vehicles.
6. Safety devices and accessories shall be subjected to air tightness test and reliability test together with the whole vehicle after vehicle assembly. 7 Vehicle assembly
7.1 Chassis modification
When the chassis needs to be modified for the installation of the chassis, the modification instructions provided by the chassis manufacturer shall be followed. If the modification instructions cannot be provided, the modification shall be carried out in accordance with the provisions of this standard.
7.1. 1 Tank truck manufacturers should inspect and approve their chassis according to the original vehicle technical conditions; [Japanese vehicle chassis must pass the overhaul inspection and be issued with a completion certificate before modification can be carried out.
7.1.2 When the chassis longitudinal beam needs to be lengthened for the installation body, welding or riveting can be used. When a welded structure is used, if the lengthened part is greater than 200mm, the joint part shall be strengthened according to the requirements of Figure 8.
Chassis longitudinal inspection
7.1.3 When installing the tank body and accessories: Do not drill holes or weld on the installation surface of the chassis longitudinal beam and the weakest part of the strength. If you want to avoid opening HG 2599-94
, it should be done at 30mm outside the upper edge of the longitudinal beam and 25mm outside the corner (see Figure 9), 2
7.1.4 When drilling holes on the chassis fabric or transverse belly, it should be done according to the technical requirements provided by the source vehicle chassis. If there are no requirements, it is recommended to follow the following regulations:, Hole spacing: large vehicles shall not be less than 70mm, medium-sized vehicles shall not be less than 60m; h. Drilling diameter: large vehicles shall not be greater than 15m, medium-sized vehicles shall not be greater than 13 mm; c. Mechanical work shall be used, and flame cutting shall not be used; Drilling is prohibited at the position with the maximum torque between the wheelbases. 7.1.5 When the chassis is modified, the rear bumper shall be installed according to the following requirements: a. The distance between the rear bumper and the rear end of the tank shall not be less than 100mm; b. The width of the rear bumper shall be slightly smaller than the width of the entire vehicle, but shall not be less than the width of the tank end; C. The rear bumper must be installed on the chassis, and the structure shall not hinder the display of the tank truck license plate, light signals and pedestrian traffic safety:
d. The rear bumper shall have sufficient rigidity and strength, and its dynamic load shall be able to withstand the force generated by twice the total mass of the fully loaded tank truck at the maximum speed.
7.1.6 The flatness tolerance of the upper plane of the frame after modification and the straightness tolerance of the upper plane and the side of the longitudinal beam shall meet the requirements of the technical components of the corresponding parts of the original chassis, and the cross-sectional shape and size of the longitudinal extension part shall meet the requirements of the drawings. 7.1.7 When changing the position of the battery, oil tank and modifying the oil and gas lines, they should be installed in a position that does not interfere with the original parts of the chassis and should be firmly fixed with support.
7.1.8 If an auxiliary fuel tank is required, the auxiliary fuel tank should be installed higher than the main tank, and the fuel return of the fuel pump should return to the main tank. 7.1.9 The exhaust pipe mouth should not point to the right side of the vehicle body. The distance between the exhaust pipe or muffler wing and the gas phase pipe, liquid phase pipe, fuel tank filling port and battery should not be less than 200mm, otherwise heat insulation measures must be taken. 7.1.10 When modifying the lubrication and gas lines, the inner diameter of the pipe should not be less than the inner diameter of the original chassis. After the pipeline is modified, an air tightness test should be carried out, and there should be no leakage at the bending part and joint. 7.1.11 When using an old vehicle chassis to modify a tanker, the bent part of the exhaust pipe should be fully inspected, and the pipes that have been thinned due to corrosion should be replaced.
When changing the location of the battery, a well-ventilated, easy-to-maintain and accessible location should be selected. The installation should be firm and reliable, and rainproof and insulation measures should be taken.
The layout of the wires should be away from the exhaust pipe of the muffler, and the distance should be greater than 200mm. When extending the wires, the specifications and wiring methods of the wires should be in accordance with the original vehicle chassis and the corresponding standards.7.1.13
The external lighting and signal system should comply with the provisions of GB4785. The rear lighting and signal should be installed on the lamp holder. It is strictly forbidden to weld them on the tank body.7.2 Installation of the tank body
7.2.1 The installation of the tank body should be carried out after the body water pressure test is qualified. After installation, the whole vehicle air tightness test should be carried out.7.2.2 The installation state of the tank body should not be concentrated on the excessive load caused by the vibration and impact during the operation of the chain car. 9.
HG.2599-—94
7.2.3 The installation position of the tank body should ensure the proper axle load distribution and roll stability, and the distance between the front end of the tank body and the cab should be kept to a minimum. When the distance has to be increased due to reasons such as lower mass distribution, the front end of the tank body support (sub-beam) should be extended as far as possible to the cab, and the shape should be gradually reduced to make the rigidity and transition (see Figure 10). The tank body is transformed into a complete sub-frame, and the vertical plane of the longitudinal center of the chassis should coincide with the vertical plane of the chassis. The deviation is not more than ±5mm within the full length of the tank body.
7.2.5 The connection between the tank body and the chassis should be firm. A vibration pad should be added between the tank support and the mounting surface of the chassis longitudinal beam. The fixing bolts should have sufficient strength. The openings or connections should be in accordance with the provisions of Articles 7.1.3 and 7.1.4. 7.3 Pipeline Installation
73.1 The tank truck adopts the loading and unloading method of bottom loading and unloading. The pipeline is installed at the bottom of the tank. The loading and unloading door, hose connector, thermometer and pressure gauge and other accessories are concentrated in the operation box on one side of the tank. 7.3.2 The layout of the pipeline shall not interfere with the transmission shaft and rotating parts of the chassis. In the static state, the gap between them shall not be less than 45mm.
7.3.3 The height of the lowest point of the liquid phase pipe and gas phase pipe from the ground shall not be less than the minimum ground clearance of the chassis of the vehicle. If it is less than the minimum ground clearance, it shall be protected by a steel plate with a thickness of not less than 6mm.
7.3.4 Except for loading and unloading hoses and hose connectors, other pipelines or connections between pipelines and rests shall not use threaded connections. 7.3.5 For prefabricated pipelines, a water pressure test shall be carried out at a pressure not less than that of the tank body water pressure test. Only after passing the test can they be installed on the tank truck. 7.3.6 On the stop valve (ball valve) of the liquid phase pipe and gas phase pipe, the discharge port for discharging residual liquid (or gas) shall be more than 200mm away from the exhaust pipe port of the vehicle, and a discharge pipe shall be installed to prevent mud and sand from clogging. 7.4 Installation of safety devices and accessories
7.4.1 The liquid level gauge installed on the upper part of the tank body should be equipped with a protective cover to prevent liquid ammonia from overflowing due to damage during rollover. 7.4.2 The safety valve should be installed in the gas phase part of the tank body, and the discharge port should face upward; the height of the exposed part should not exceed 150mm, and it should be protected if it exceeds; and there should be dust, water, and anti-freeze measures. 7.4.3 The pipe of the pressure gauge should be led out from the gas phase pipe. A load-stop valve should be installed on the pipe. 7.4.4 The temperature sensing part of the thermometer should be installed in the internal phase. 7.4.5 The fire extinguisher should be installed at the connection away from the fishing hose. If a full fire extinguisher is used, it should be installed in an appropriate position of the vehicle one by one. The fire extinguisher should adopt an installation structure that can be quickly removed. 7.4.6 The static elimination grounding chain of the tank truck must ensure that the tank body and the pipeline and the tank body and the chassis can be grounded so that their potentials are the same. The cross-sectional area of the wire connecting the body and the ground equipment should not be less than 5.5mm. One end of the wire should be connected to the chassis, and the other end should be able to be connected to the terminal installed on the ground.
7.4.7 The operating box is installed on one side of the liquid and gas pipe outlets. The accessories installed in the operating box should have a space of not less than 50mm from the outer edge of the operating box.
7.4.8 When the wheelbase of the tank truck is greater than 4000mm, guardrail protection devices should be installed on the lower part of both sides of the truck in accordance with GB11567. In the unloaded state, the height of the lower edge of the guardrail from the ground should not be greater than 450mm. 7.4.9 The display fence, platform and pedal board shall have sufficient rigidity and strength. Their structure shall be able to withstand a load of more than 180 kg and be installed on a fixed support. They shall not be welded to the tank body. HG2599-94
7.4.10 The width and height of the mud guard shall not hinder the normal operation of the tire and anti-skid chain: when fully loaded, the distance between the highest point of the tire and the tire cover shall not be less than 120 mm.
8 Test method
8.1 Determination of the main parameters and basic performance of the whole vehicle 8.1.1 The determination of the mass parameters, center of gravity position and external dimensions of the whole vehicle shall be in accordance with the requirements of Articles 3.2 to 3.4 of ZBT50003 and shall comply with the provisions of Articles 3.1, 3.4 and 3.6 of this standard.
8.1.2 The maximum speed test and the climbing test shall be carried out in accordance with the requirements of GB1334, and the braking performance test shall be carried out in accordance with the requirements of JB3689, and shall comply with the provisions of 3.4 of this standard.
8.1.3 The maximum roll angle during empty cutting shall be determined in the following way: drive the tank car onto the tilt test bench, make the longitudinal center line of the tank car parallel to the center line of the test bench shaft, brake the car, and use a rope to check the tank car in the direction where it will slip or overturn (but the rope shall not be pre-tensioned): thereafter, the test bench is slowly and steadily tilted until the tank car slips or overturns, and the angle on the dial is recorded. If it is greater than the specified angle, it is qualified.
8.2 Body water pressure test and internal volume determination
8.2.1 The water pressure test of the tank body shall be carried out in accordance with Article 10.9 of GB150 after the tank body is subjected to stress relief heat treatment, and shall comply with the provisions of Article 3.3 of this standard.
8.2.2 During the water pressure test, the internal volume of the tank shall be measured, which shall comply with the provisions of Article 4.3.2. 8.3 Air tightness test of the whole vehicle
8.3.1 The air tightness test of the tank shall be carried out in accordance with Article 10.9 of GB150 after the water pressure test is passed, which shall comply with the provisions of Article 3.3. 8.3.2 For vehicles with modified brake air circuits, the brake system shall be tested for air tightness after modification. During the test, start the engine to inflate the brake air circuit. When the pressure reaches 0.5MPa, maintain the pressure for 30 minutes. The brake air circuit and the weld shall be tested for air tightness. There should be no leakage, and it should comply with the provisions of Article 3.4. 8.4 Safety valve commissioning and emergency shut-off valve test 8.4.1 The commissioning and inspection of the safety valve can be carried out at any time, and it should comply with the provisions of HG5-1587 and Articles 6.1 and 2 of this standard. After inspection and adjustment, it should be sealed.
8.4.2 The emergency shut-off device test is carried out together with the air tightness test of the tank body after the tank car is assembled, and it should comply with the requirements of HG5-1588. 8.5 Driving test
8.5.1 The driving test of the tank car should comply with the provisions of ZBT50003. 8.5.2 Before the test vehicle is driven, the actual medium is simulated to fill the tank body with water according to the maximum filling volume of the tank car. 8.5.3 At the beginning of the driving test, the test vehicle is fully checked and adjusted to reach the specified state. 8.5.4 During the driving test, all covers, manholes and valves of the test vehicle shall be tightly closed, and all joints shall be coated with leak tester for leakage inspection. 8.5.5 The connection between the chassis and the Weixiu shall be painted with white paint to check whether the connection between the tank body and the chassis is loose or displaced. 8.5.6 The inspection during and after the driving test shall meet the following requirements: a. The tank body and accessories shall be free of damage, cracks, deformation and desoldering; b. The fastening state shall be good, the bolts shall not be loose, and there shall be no relative displacement between the tank body and the chassis; c. The manhole cover, valve and weld shall be There should be no water leakage, air leakage, or oil leakage; d. The transmission system should not shake, the braking performance should be reliable, and there should be no cracks or deformation near the chassis longitudinal beam openings and welds; e. The emergency shut-off device for loading and unloading valves should be operated 5 times each, and should be sensitive and reliable; f. The liquid level gauge should be reliable, and the measuring mechanism should be sensitive and not stuck during filling and draining, and the liquid level gauge indication should be within the measurement accuracy range:
8.5.7 If a fault occurs during the driving test, it should be analyzed in time, the cause should be found out and measures should be taken, and the test can be continued after improvement according to the fault situation.3 The maximum roll angle during empty cutting is measured in the following way: drive the tank car onto the tilt test bench, make the longitudinal center line of the tank car parallel to the center line of the test bench shaft, brake the car, and use a rope to check the tank car in the direction of slipping and overturning (but the rope must not be pre-tensioned): thereafter, the test bench is slowly and steadily tilted. When the tank car slips or overturns, the angle on the dial is recorded. If it is greater than the specified angle, it is qualified.
8.2 Hydrostatic test of tank body and determination of internal volume
8.2.1 The hydrostatic test of the tank body shall be carried out according to Article 10.9 of GB150 after the tank body is subjected to stress relief heat treatment, and shall comply with the provisions of Article 3.3 of this standard.
8.2.2 During the water pressure test, the internal volume of the tank shall be measured, which shall comply with the provisions of Article 4.3.2. 8.3 Air tightness test of the whole vehicle
8.3.1 The air tightness test of the tank shall be carried out in accordance with Article 10.9 of GB150 after the water pressure test is passed, which shall comply with the provisions of Article 3.3. 8.3.2 For vehicles with modified brake air circuits, the brake system shall be tested for air tightness after modification. During the test, start the engine to inflate the brake air circuit. When the pressure reaches 0.5MPa, maintain the pressure for 30 minutes. The brake air circuit and the weld shall be tested for air tightness. There should be no leakage, and it should comply with the provisions of Article 3.4. 8.4 Safety valve commissioning and emergency shut-off valve test 8.4.1 The commissioning and inspection of the safety valve can be carried out at any time, and it should comply with the provisions of HG5-1587 and Articles 6.1 and 2 of this standard. After inspection and adjustment, it should be sealed.
8.4.2 The emergency shut-off device test is carried out together with the air tightness test of the tank body after the tank car is assembled, and it should comply with the requirements of HG5-1588. 8.5 Driving test
8.5.1 The driving test of the tank car should comply with the provisions of ZBT50003. 8.5.2 Before the test vehicle is driven, the actual medium is simulated to fill the tank body with water according to the maximum filling volume of the tank car. 8.5.3 At the beginning of the driving test, the test vehicle is fully checked and adjusted to reach the specified state. 8.5.4 During the driving test, all covers, manholes and valves of the test vehicle shall be tightly closed, and all joints shall be coated with leak tester for leakage inspection. 8.5.5 The connection between the chassis and the Weixiu shall be painted with white paint to check whether the connection between the tank body and the chassis is loose or displaced. 8.5.6 The inspection during and after the driving test shall meet the following requirements: a. The tank body and accessories shall be free of damage, cracks, deformation and desoldering; b. The fastening state shall be good, the bolts shall not be loose, and there shall be no relative displacement between the tank body and the chassis; c. The manhole cover, valve and weld shall be There should be no water leakage, air leakage, or oil leakage; d. The transmission system should not shake, the braking performance should be reliable, and there should be no cracks or deformation near the chassis longitudinal beam openings and welds; e. The emergency shut-off device for loading and unloading valves should be operated 5 times each, and should be sensitive and reliable; f. The liquid level gauge should be reliable, and the measuring mechanism should be sensitive and not stuck during filling and draining, and the liquid level gauge indication should be within the measurement accuracy range:
8.5.7 If a fault occurs during the driving test, it should be analyzed in time, the cause should be found out and measures should be taken, and the test can be continued after improvement according to the fault situation.3 The maximum roll angle during empty cutting is measured in the following way: drive the tank car onto the tilt test bench, make the longitudinal center line of the tank car parallel to the center line of the test bench shaft, brake the car, and use a rope to check the tank car in the direction of slipping and overturning (but the rope must not be pre-tensioned): thereafter, the test bench is slowly and steadily tilted. When the tank car slips or overturns, the angle on the dial is recorded. If it is greater than the specified angle, it is qualified.
8.2 Hydrostatic test of tank body and determination of internal volume
8.2.1 The hydrostatic test of the tank body shall be carried out according to Article 10.9 of GB150 after the tank body is subjected to stress relief heat treatment, and shall comply with the provisions of Article 3.3 of this standard.
8.2.2 During the water pressure test, the internal volume of the tank shall be measured, which shall comply with the provisions of Article 4.3.2. 8.3 Air tightness test of the whole vehicle
8.3.1 The air tightness test of the tank shall be carried out in accordance with Article 10.9 of GB150 after the water pressure test is passed, which shall comply with the provisions of Article 3.3. 8.3.2 For vehicles with modified brake air circuits, the brake system shall be tested for air tightness after modification. During the test, start the engine to inflate the brake air circuit. When the pressure reaches 0.5MPa, maintain the pressure for 30 minutes. The brake air circuit and the weld shall be tested for air tightness. There should be no leakage, and it should comply with the provisions of Article 3.4. 8.4 Safety valve commissioning and emergency shut-off valve test 8.4.1 The commissioning and inspection of the safety valve can be carried out at any time, and it should comply with the provisions of HG5-1587 and Articles 6.1 and 2 of this standard. After inspection and adjustment, it should be sealed.
8.4.2 The emergency shut-off device test is carried out together with the air tightness test of the tank body after the tank car is assembled, and it should comply with the requirements of HG5-1588. 8.5 Driving test
8.5.1 The driving test of the tank car should comply with the provisions of ZBT50003. 8.5.2 Before the test vehicle is driven, the actual medium is simulated to fill the tank body with water according to the maximum filling volume of the tank car. 8.5.3 At the beginning of the driving test, the test vehicle is fully checked and adjusted to reach the specified state. 8.5.4 During the driving test, all covers, manholes and valves of the test vehicle shall be tightly closed, and all joints shall be coated with leak tester for leakage inspection. 8.5.5 The connection between the chassis and the Weixiu shall be painted with white paint to check whether the connection between the tank body and the chassis is loose or displaced. 8.5.6 The inspection during and after the driving test shall meet the following requirements: a. The tank body and accessories shall be free of damage, cracks, deformation and desoldering; b. The fastening state shall be good, the bolts shall not be loose, and there shall be no relative displacement between the tank body and the chassis; c. The manhole cover, valve and weld shall be There should be no water leakage, air leakage, or oil leakage; d. The transmission system should not shake, the braking performance should be reliable, and there should be no cracks or deformation near the chassis longitudinal beam openings and welds; e. The emergency shut-off device for loading and unloading valves should be operated 5 times each, and should be sensitive and reliable; f. The liquid level gauge should be reliable, and the measuring mechanism should be sensitive and not stuck during filling and draining, and the liquid level gauge indication should be within the measurement accuracy range:
8.5.7 If a fault occurs during the driving test, it should be analyzed in time, the cause should be found out and measures should be taken, and the test can be continued after improvement according to the fault situation.
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