管道酸洗方案

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1、目录 content1. 目的 purpose2. 适用范围adapted scope3. 编制依据work basis4. 清洗的步骤cleaning proceed5. 清洗后的质量标准the quality standards of cleaning6. 公用设施public service7. 安全管理措施及组织安全管理体系 HSE managed measure and the organized managed chart8. 施工机具及手段用料construction tools, methods and materials9. 1、目的 purpose为了确保上海拜耳异氰酸酯和

2、聚醚项目TDI联合装置清洗后的不锈钢管道内表 面能满足防腐及清洁度的要求，特编制本方案。In order to satisfy the require of the antisepsis and the cleaning after stainless pipe inner cleaning to workout this scheme especially.2、适用范围 adapted scope 本方案仅适用于本次不锈钢管道的化学清洗工程中，所有管道内表面清理、脱 脂、酸洗、钝化操作及清洁度的控制。 This scheme adapt to all pipes inner cleaning

3、, degreasing, demin water clean, passivation and controlling of cleaning, including the stainless pipes.3、编制依据work basis本清洗方案的编制参考如下资料：this scheme is worked according to the following documents: 中华人民共和国化工行业标准HG/T2387-92工业设备化学清洗质量标准；The Peoples Republic of China Chemical Industry Standard HG/T2387-92

4、 chemical cleaning of indus trial equipmen t, qual ity st andards; 脱 脂工 程及验 收规范 HG20202-2000 Skim engineering and acceptance HG20202-2000 工业金属管道工程施工及验收规范(GB50235-97)the cons true tion and accep ted standard of the industry mental pipe project 石油化工有毒、可燃介质管道工程施工及验收规范(SH3501-2002) cons true tion and th

5、e accepted standard of sinoec poison and buring medium project(SH3501-2002) 石油化工钢制管道工程施工工艺标准(SH/T3517-2001 ) the cons true tion standard of sinopec steel pipe project(SH/T3517-2001) 中国蓝星化学清洗总公司大型装置(包括引进装置)化学清洗施工规范；Chinese blue star cleaning companylarge set chemical cleaning construction standard(in

6、cluding the set bringed in 中国蓝星化学清洗总公司化学清洗质量保证手册；chinese blue star chemical cleaning companythe manual of ensuring chemical cleaning quality4. 清洗的步骤cleaning proceed本工程清洗采用化学清洗的工艺方法，对管道进行化学清洗。本次清洗的管道 均为不锈钢管线，根据现场实际情况将管线分组分批进行循环清洗。清洗步骤为: 水冲洗-脱脂-脱脂后水冲洗-酸洗-酸洗后水冲洗-钝化-水冲洗。The cleaning pipes are stainlessa

7、n carboninthisproject, thepipe will be separated each group to clean according to the material and actual condition. Theprocess as follows: flushing-degrease-water flushing-demin water cleaning-passivation-water flushing.本工程的清洗工作范围：不锈钢管道DN32、DN48、DN80,共计150米the cleaning scope of this project:stainle

8、ss pipe DN32,DN48,DN80,totally about150m.清洗工作简要描述：将被清洗管道串联或并联成一个密闭的循环系统,利用循 环泵，将清洗液体注入被清洗管道内部，进行强制循环。Brief description of cleaning work： connecting the pipes should be cleaned to form a circle system, the pump will make the cleaning water to flush the pipe insides. 4.1 水冲洗water flushing主要是去除管线内表面中的浮

9、尘、脱落的金属氧化物及其它机械清理后遗留的 其它污物;脱脂、酸洗、钝化后的水冲洗是为了去除管线内表面遗留的溶剂，当PH 值在6-8时水冲洗完成，PH值采用PH试纸测定，每30分钟一次Wipe off the dusty, metal oxid and others filth left behind other mechanical cleaning; after degreasing, acid cleaning, passivation the water flushing will be used to wipe off the solvent inside of the pipes,

10、each 30 minutes use the PH paper to check PH value. When the PH value is between 6-8, water flushing work is finished.4.2脱脂(常温)degrease(normal temperature)脱脂的目的是除去被清洗系统内各种油污，且可除去有机物等的物理附着物， 使酸洗过程中的作用成份更完全、彻底地同清洗对象的内表面接触，从而促进金 属氧化物溶解，保证达到均一的酸洗效果。Thepurposeofdegreasingistoremoveallkindsofmachineoil,gr

11、aphite, rustpreventingoilandotherorganicsinthesystem,andmaketheeffective ingredients in the pickling process touch the dirt surface more completely andthoroughly,thuspromotethedissolutionofmetaloxidesanddirt,and guarantee reaching the good cleaning effects.脱脂的溶剂采用6.0-8.0%脱脂剂A+1.0-2.0%表面活性剂+3.0%助剂配制而

12、成;the degreasedwaterismadeof6.0-8.0%degreasedrugA+1.0-2.0%activesurface drug+3.0% aid drug.脱脂剂浓度采用酸碱中和滴定法测定，每30分钟检测一次，分别对临时清洗系统 进液、回液取样分析，当系统进、回脱脂液药剂浓度趋于平衡，即可结束脱脂。检测进、回液药剂浓度值相当，浓度数值控制在0.2%范围内。When the thickness of passing in and out water is about same , the woke will be finished, each 30 minutes ch

13、eck one time with the way of titration acid and alkali. Detection into the back to liquid pharmace uti cal concen tration equivale nt to 0.2% in the concentration of values within the control.4.3酸洗(常温) acid cleaning( normal temperature)酸洗的目的是利用酸洗液与管道焊接时产生的热影响区及焊皮进行化学和电化学 反应，生成可溶性物质，以除去污物的过程，同时为钝化创造条

14、件，酸洗是整个 化学清洗过程的关键步骤。The aim is to use pickling acid lotion and pipe welding heat affected zone resulting from welding leather and chemical and elec trochemical reac tion of soluble mat erial, to remove dir t in the process, while creating conditions for the passivation, pickling is the a key step in

15、 the process of chemical cleaning.根据锈蚀程度及设备管线材质确定酸洗配方。酸洗时可选择不同的添加剂，为了 避免储管道在酸洗时受到氢离子腐蚀和三价铁离子的腐蚀作用，因此，在酸洗体 系中，应投加缓蚀剂等助剂。Select the cleaning medicament according to the rust and material of equipment. The corrosion inhibitor must be used to avoid the systems corrosion by H+and Fe 3+.酸洗药剂采用8.0-10.0%HN0

16、3+ (0.5-1.5%) HF+ (081.0%)缓蚀剂LAN-826配制 而成。The acid water is made of 8.0T0.0%HN03+ (0.5T.5%) HF+ (0.8-1.0%) delaying erode LAN-826 排尽冲洗水，充入配制好的酸洗液进行酸洗。酸洗时，定时取样分析，定时进行 排污。通过对进、回液取样分析，检测系统内药剂浓度的含量的变化，来确定清 洗的时间，通过酸碱滴定法检测出系统内酸液浓度含量基本达到平衡，药剂浓度 数值控制在0.2%范围内。即可结束酸洗。也可通过监视管段直观检查效果。酸洗 循环的时间一般为2小时左右。Rinse wate

17、r drained, pumped into the washing solutions were prepared from acid pickling. Acid, the time the sample analysis, regular sewage. Through into the back to liquid sample analysis, detection system, changes in pharmaceutical concentration levels to determine the cleaning time, detected by acid-base t

18、itration system, achieving a balance of acid concentrations, numerically controlled pharmaceutical concentration range of 0.2% inside. Pickling can be concluded. Can also be visualinspection by monitoring the effect of tube sections. Acid cycle time is 2 hours.4.4钝化 passivation钝化采用的溶剂为33%钝化剂+0.8%缓蚀剂

19、（lan-826） .； the passivation wateris made of 33% passivation drug+0.8% （lan-826）delaying erode.通过钝化的方法，可使不锈钢金属表面的金属成分与钝化液（硝酸）生成一层薄的复合金属盐（即钝化膜），该盐能防止金属被腐蚀，提高管道内表面的耐腐蚀 性。钝化的时间一般为1.5小时左右。It will form a passivation film after pickling, and improve the corrosion of pipeline inner surface.排尽冲洗水，将配制好的钝化液由清

20、洗槽加入管道，开始循环，钝化过程中，定时取样分析，定时进行排污。通过对进、回液取样分析，检测系统内药剂浓度、铁离子浓度的含量的变化，通过酸碱滴定法检测出系统内钝化液浓度、铁离子含 量基本达到平衡，即可结束钝化工序。Discharge all the water, fill the system with fresh water and circulate.Gradually add passivation chemicals,mix them evenly and carry out positive and negative direction circulation. When the c

21、oncentration of the liquid and Fe 2+/Fe 3+ are steady, the step can be ended.4.5 纯水冲洗 Pure water flushing钝化结束，排尽钝化液后，用新鲜水进行冲洗，目的是除去残留的钝化液及洗落的固体颗粒。当出水PH=6-7时，即可结束水冲洗。Thepurposeistoremovetheresidualwastedacidwaterandthesoliddrop.When the PH is approachneutralismand theflushing is cleaning, the step co

22、uld be finished.工艺条件 Process conditions流 速 Flow rate1. 01.2 m/s时 间Time12 h测试项目Test itemsPH 值PHltime/30min4.6清洗废液处理方式 CLEANING WASTE WATER TREATMENT METHOD 冲洗废水处理 Disposal of flushing watera) 冲洗废水不含化学物质，PH值为中性，符合GB8978-1996污水综合排放 标准规定的排放要求，因此可以直接排放到雨水系统。The flushing water does not contain chemical ma

23、tter and the PH is 7 and therefore, can be discharge to rain water system.b) 脱脂后冲洗水和酸洗后的冲洗水进行中和，中和后的废水外运处理。The flushing water after degreasing and pickling should to make PH value 69, and move to treatment plant. 脱脂、酸洗、钝化废液处理 Disposal of pickling and passivation wastewatera) 清洗废液中和至PH达到69。The chemic

24、al cleaning wastewater need neutralize PH is 69.b) 中和后的废水外运到当地污水处理厂集中处理。After neutralization, the cleaning wastewater shall be move to treatment plant.5清洗后的质量标准the quality standards of cleaning化工行业标准工业设备化学清洗质量标准(HG/T2387-2007)以及拜耳的 相关技术要求。以双方确定的清洗技术要求为准。The standards: (HG/T2387-2007), and Bayers spe

25、cification. The cleaning demands which the both sides ensured.被清洗的管道内表面清洁、无锈，表面经外观检查合格，无惰性金属置 换析出、无金属粗晶析出的过洗现象，应形成完整的钝化膜。Thecleanedmetalsurfaceofpipeisclean,almosthasnoremained oxides and welding ashes, the cleaned surface have no secondary floating rust and pit corrosion, no metal coarse is precipi

26、tated, and forms complete passivated film.被清洗金属表面无局部腐蚀，酸洗过程中试片的均匀腐蚀速度应小于2g/mhNo partly corrosion on cleaned metal surface. The corrosion rateshould be less t han 2 g/m2 h in pickling process. 清洗后的进行蓝点检测合格It takes Blue -spot checking the inner surface. 符合委托方提出的其它质量要求。The pickling and passivation effe

27、ct can get owners other quality demand.6公用设施：public service水：脱盐水，总量 10m3。Water: doff brine, the gross 10 m3气：压力 0.5-lMPa。Gas:pressure 0.5TMPa.电：7.5KW ( 台)，三相动力电源。Electricity:7.5KW(each one), three driving power supply.7安全管理措施及组织安全管理体系HSE managed measure and theorganized managed chart7.1 安全措施 safety

28、precautions7.1.1清洗现场除操作人员外，闲杂人员一律不得入内；all people should not enter on cleaning site except the operator.7.1.2 清洗施工人员均需进行上岗前培训持证上岗作业； the operator with certificate should have a training before working.7.1.3 清洗作业前，参加清洗人员对现场应充分了解，并熟悉周围的消防设施和 器材； before cleaning, all cleaning operator should knowwell of

29、 the site, the fire control establishment and the instrument.7.1.4清洗现场必须具备抢修材料及器具；it should have the rushing to repair material and instrument.7.1.5运输化学药品禁止手抱肩扛等原始方法；it is forbided to transport the chemical drug withthe old wayofholdingbyhanding and beingpickaback.7.1.6清洗操作人员在作业中，须认真执行操作规范，杜绝违章操作;th

30、e cleaning operator should follow the operated standard in the whole cleaning work. 7.1.7清洗现场禁止吸烟焊接气割和其它热加工作业；it is forbided to smoking, welding, gas-cutting and other heating work.7.1.8清洗作业中，操作人员需配备防护设施.如防护服手套面罩安全帽等；the operatorshouldhavethesafeguardinthecleaningwork,suchasexposure, glove7.1.9设置临时急

31、救设施及药品；Provision of temporary first aid facilities and medicines7.1.10对操作人员进行安全教育，强化安全第一的思想，其他有关措施应严 格执行中国蓝星化学清洗总公司清洗工程安全操作规程。The opera tors to conductsafety education, strengthen the safety first mentality,other measures should strictly enforce the China Blue Star Chemical Cleaning Company cleansin

32、g engineering safety operating procedure8、施工机具及手段用料 construction tools, methods and materials8.1化学清洗施工机具一览表：序号 No.名称Name规格型号 Specifications Model单位Units数量Amount备注Not es9清洗泵（带电机）台1管道清洗10高压清洗机台1管道清洗11清洗槽个112温度计支1013酸洗槽台18.2手段用料一览表序号No.名称Name规格型号 Specifications Model单位 Uni ts数量 Amount备注Not es2塑料管Plas t

33、ic pipeDN50M80各管段之间连接The pipe connec tions bet ween theDN40M100各管段之间连接The pipe connec tions bet ween the3型钢St eel12M30临时支撑制作Temporary support to production4塑料法兰 Plastic FlangeDN50个A8连接塑料管Connec ting plastic pipeDN40个A8连接塑料管Connec ting plastic pipeDN25个A27连接塑料管Connec ting plastic pipe5橡胶板Rubber pla t

34、e。=3M23临时垫片制造Temporary gasket manufacturing7阀门ValvesPVC-U DN50个A4配法兰、螺栓、垫片 (临时管道用)With flanges, bolts, gaskets (Temporary Pipeline)PVC-U DN40个A48压力表ManometerPN2.0MPa块Block2用于泵出口测压9温度计 Thermometer支Support310消防水带Fire hoseDN65支Support2管道清洗排水12橡皮手套付30酸洗13石棉板。=3M25临时垫片、盲板14封箱带卷20管道封口15聚四氟乙烯带卷10丝口连接16塑料布kg20管道封口17手电筒支3配若干电池（检查用）序号No.名称Name规格型号 Specifications Model单位 Uni ts数量 Amount备注Not es18探照灯台6夜间照明19不锈钢丝2.5米350塑料管绑扎