纯化水管线酸洗钝化方案

附件20卫生级管路酸洗钝化方案SanitaryPipeChemicalPickled&PassivationProcedure起草/审察签字日期起草人审察/赞同1目录TABLEOFCONTENTS1............编制方案的依照Basisofschemecompilation错误!不决义书签。2...............................工作范围Workingscope错误!不决义书签。3............................冲刷工艺Cleaningprocess错误!不决义书签。4............................冲刷过程Cleaningprocess错误!不决义书签。5......................废液办理Wasteliquortreatment错误!不决义书签。6........甲方供应的条件Conditionsuppliedbytheowner错误!不决义书签。7............................临时配管Temporarytubing错误!不决义书签。8...........................检验与查收Testandaccept错误!不决义书签。9.................................................安全错误!不决义书签。231编制方案的依照Basisofschemecompilation1.1管道冲刷的必要性Necessityofpipingcleaning纯化水不锈钢管道在使用前，要进行脱脂、酸洗、钝化和消毒办理，管道才能达到生产使用的技术要求。Beforeusedstainlesssteelpipingforpurifiedwatershouldbedegreased,pickled,passivityanddisinfected.Onlyinthiswaycanpipingmeettechnicalneedsofproductionandusage.1.2《脱脂工程施工及查收规范》HG20202-2000。ConstructionandAcceptanceCriteriaofIndustrialPiping1.3《工业设施化学冲刷质量标准》HG/T2387-2007QualityCriteriaofChemicalCleaningforIndustrialEquipment1.4VWS供应的图纸DrawingssuppliedbyVWS1.5管线的材质为全部为316L，如有其他材质，冲刷前必定说明。Materialofpipelineisall316L.Giveadescriptionofthematerialbeforecleaningifothermaterialsareused.2工作范围Workingscope主要为卫生级不锈钢SS316L管道MainlyforsanitarySS316Lpipe.2.1从纯水制造机到纯水TANK接口前级的循环管道；PipesfromOriontowatertankandpipesofwatertankreturningtothefronttank.2.2纯水循环管道；PWloopdistributionPipes.3冲刷工艺Cleaningprocess43.1采用我公司多年成熟的不锈钢管道冲刷工艺。Adoptcleaningprocessforstainlesssteelpipewhichwearegoodat.3.2管道的冲刷工艺为：Pipingcleaningprocessisasfollows:临时配管建立循环回路formcirculation——水冲刷waterflush——脱脂degrease——水冲刷rinsebywater——酸洗pickling,钝化passivation——水冲刷rinsebywater——系统恢复systemreset3.3设施、管线系统内不宜冲刷的部件：Componentsintheequipmentandpipingthatarenotsuitabletobecleaned冲刷系统中的仪表类（一次仪表、二次仪表及仪表传感器）和UV杀菌灯、热交换器（板式及管壳式）对冲刷液敏感的部件应临时拆掉。Othercomponents,suchas1stloopinstrument,2ndloopinstrumentandothertransmitter,UV,HX(includingplatetypeandtube/shell)thatarenotinconformitywithmaterialandaresensitivetocleaningagent,suchasflowmeter,conductivitymeter,levelmeter,wiring,tank,etcshouldbedismantledtemporarily.3.4管线系统内不参加冲刷的短管等拆掉的部件采用浸泡冲刷，冲刷完成后经检验合格后用塑料保鲜膜包扎，等管线系统冲刷完成后再安装复位。Allcomponentsdidnotinvolvedonthepipelinetobesoakedandcleaned.Aftercleanedandtested,itmustbepackedwithplasticfilm.Installedandpositionedafterpipecleanfinished.3.5冲刷流程Cleaningprocess3.5.1.全部需要冲刷的管道用临时管道连接形成冲刷循环系统，采用循环冲刷，冲刷时建立一个循环回路.Allpipingthatneedcleaningshouldbeconnectedbytemporarypipingtoformcirculationsystem.Circulating5cleaningisusedandoneloopwasformedwhenproceedingwithcleaning.3.5.2.冲刷流程图4冲刷过程Cleaningprocess全部冲刷系统的过程是相同的。Allcleaningsystemhavethesameprocess.4.1人工办理Manualhandling4.1.1.管线在冲刷前要做全面检查，设施材质和方案中所列要一致。Pipelinesshouldbeinspectedintheoverallperspectivebeforecleaningandmakesurethatequipmentmaterialisinconformitywiththatlistedinthescheme.4.1.2.不参加冲刷的被隔断的仪表阀门等要在冲刷前检查确认Isolatedinstrumentsandvalvesthatarenotcleanedshouldbecheckedbeforecleaning。4.1.3.测试样品必定包含两个新焊的，未冲刷的焊缝。一个安装在将要冲刷的管路中，别的一个放在化学冲刷罐内;.4.2水冲刷：水冲刷及试压的目的在除去管线内表面积灰、泥沙、零散的金属氧化物及其他松懈污垢，并在模拟冲刷状态下对临时冲刷回路进行泄漏检查。Rinsewithwater.Rinseandpressuretestaimtoremoveashes,mudandshedmetallicoxideandotherloosedirtonthesurfaceofpipelinesandproceedwithleaktestontemporarycleaningloopunderthecircumstancesofcleaningstimulation.用纯化水（氯离子小于）进行冲刷，冲刷时控制进出水平衡。冲刷的同时检查冲刷循环系统可否有泄漏等情况发生，倘如有，在冲刷剂增加前6要办理好。Rinsewithpurifiedwater(chlorineionislessthan.Inrinseprocesscontrolthebalancebetweenincomingandoutgoingwaterandcheckifcirculatingsystemleaks.Ifso,doitwellbeforeaddingcleaningagent.4.3脱脂：脱脂办理的目的系统内表面在制作、安装、过程中产生的油脂，使酸洗液能完满，完整地和系统内表面接触，从而使冲刷完整，钝化膜完满；Degrease.Itaimstodegreasetheoilproducedinthefabrication,installationofinnersurfaceofsystemtomakepicklingagentgetinfullcontactwithinnersurfacesystem.Thereforecleaningcanbefinishedfullyandpassivationmembraneisincompletesituation.4.3.1.操作步骤，系统加入纯化水（氯离子小于）至预定液位，开始循环，并加入碱洗药剂。Procedure.Injectpurifiedwater(chlorineionislessthanintothesystemandbeginthecirculation.Andaddalkalinecleaningmedicamentforstainlesssteelanddegreasingfinishes.4.3.2.工艺条件：Process温度temperature常温normaltemperature循环时间circulatingtime2小时hours循环时间可依照天气、管道复杂情况合适延长或缩短。Circulatingtimecanbelengthenedorshortenedaccordingtotheweatherandpiping.4.3.3.脱脂药剂：Degreasingmedicament序名称号NameNo1氢氧化钠直到其浓度为2%-3%74.3.4.测试项目：ItemstobetestedPH1次/半小时once/halfhour脱脂液PH要求保持在12以上，当PH小于12时应增加氢氧化钠。PHofDegreasingagenttobekeptasabove12andsufficientdegreasingagenttobeadded.PH测试使用PH试纸PHcheckedwithPHtestpaper4.4水力冲刷：水力冲刷的目的是除去脱脂后零散的污物，并将系统表面残留的脱脂液冲刷干净。Waterrinsetogetridofshedordureandflushremainingdegreasingagentonsystemsurfaceclean.4.4.1.操作步骤，排尽系统内脱脂液，用大量水冲刷。Operationprocedure.Draindegreasingsolutioninthesystemandflushthesystemwithenoughwater.4.4.2.测试项目，用视察觉看冲刷水至透明无微粒，测定PH小于9。Itemstobetested.CheckflushwatertobetransparentwithnoparticulatevisuallyandmakesurePHvaluelessthan9.PH2次/半小时twice/halfhourPH测试使用PH试纸，当PH小于等于9时水冲刷完成。PHcheckedwithPHtestpaperandwaterflushfinishedwhenPH<9.4.5酸洗：酸洗的目的是利用酸洗液将金属表面的铁锈氧化物等污垢进行化学和电化学反应，生成可溶性物质，并利用酸洗液的冲刷作用除去污垢。Pickling.Picklingaimstomakedirtlikerustedoxideonthesurfaceofmetalproceedwithchemicalandelectromechanicalreactiontoproducedissolublematerialandgetridofdirtwith8picklingsolution.4.5.1.操作步骤，排净系统水冲刷残液后，随即系统加水至一定液位循环，加入不锈钢专用酸洗剂，随后补充水至控制液位。冲刷过程中如期排污排空。Operationprocedure.Afterremainingrinsesolutionisdrainedaway,injectacertainamountofwaterintothesystemtoacertainlevelforcirculation.Addspecialpicklingmedicamentforstainlesssteelintoit.Theninjectacertainwatertocontrollevel.Blowdownthewasteperiodicallyduringcleaning.4.5.2.工艺条件：Processsituation冲刷温度cleaningtemperature常温normaltemperature循环时间circulatingtime2小时hours4.5.3.酸洗钝化药剂：序名称号NameNo1柠檬酸，保证浓度在10%~15%4.5.4.测试项目：ItemstobetestpH值PHvalue1次/半小时twice/halfhour酸洗液PH要求小于等于1，当PH大于１时应增加柠檬酸，保证浓度在10%~15%。PickedchemicalPHlessthan1andpickedchemicaltobeaddedincasePHishigherthan1.PH测试使用PH试纸PHcheckedwithPHtestpaper4.6水冲刷：钝化完成后的水冲刷是为了把残留的钝化液除去。9Waterrinse.Waterrinseafterfinishingpassivationistogetridofremainingpassivationsolution.4.6.1.钝化结束后，排尽钝化液洗液，用纯化水（氯离子小于）进行冲刷，除去残留的钝化液，当PH直凑近中性Ph>6，电导率差小于μs/cm，即可结束。Afterfinishingpassivation,drainawaysolutionforpassivationandflushwithpurifiedwater(chlorineiconislessthantoremoveremainingpassivationsolution.WhenPHisclosetotheneutralization(pH>6),differenceofconductivitylessthan1μs/cmpassivationfinishes.4.6.2.工艺条件Processcondition冲刷温度cleaningtemperature常温normaltemperature4.6.3.测试项目：ItemstobetestedPH2次/半小时twice/halfhour电导率conductivity2次/半小时twice/halfhourPH测试使用PH试纸PHtestbyPHtestpaper.使用电导率仪测定电导率Condtestedbycond.Meter.4.7系统恢复，冲刷完成后将系统恢复原样。Systemreset.Getthesystembackafterfinishingcleaning.4.8若是系统长时间不投入使用，建议用氮气封存。Ifthesystemisnotputintouseforalongtime,nitrogenissuggestedforsealing.5废液办理Wasteliquortreatment105.1各冲刷过程中的冲刷水，未增加冲刷剂，可以直接排放。Flushwaterwithoutcleaningadditiveduringcleaningcanbedischargeddirectly.5.2酸洗液的废液，钝化液的废液，用槽罐车把废水运输到废水办理厂办理排放。Wasteliquorofpicklingsolutionandgreasingsolutionshouldbedeliveringwithtankcartowastewatertreatingplantforhandlinganddischarging.6甲方供应的条件Conditionsuppliedbytheowner甲方负责供应予下公用设施：Thefollowingutilitiesareprovidedbytheowner.6.1水：全程采用纯化水，纯化水要求氯离子小于，使用ORION纯化水.Purifiedwaterisusedthroughthesystemandpurifiedwatershouldincludelessthanchlorineicon.Orionwillprovidethepurifiedwaterforchemicalpickledandpassivation..6.2电源(冲刷时使用纯化水泵)。Powersupply.Purifiedwaterpumpisusedwhencleaning.6.3干燥无油的压缩空气或氮气，MPa。DrycompressedairornitrogenwithnooilofMPa.7临时配管Temporarytubing7.1临时配管是指将冲刷系统中管道连接起来，形成冲刷循环回路，冲刷完成后需要拆掉的管道和设施。TemporarytubingisthepipingandfacilitythatneedbedismantledaftercleaningConnectpipinginthecleaningsystemtoformcirculatingloop.117.2临时配管用软塑料管。Temporarytubingadoptssoftplastictube.8检验与查收Testandaccept8.1钝化表面目测，钝化膜完满，颜色一致。Checkthesurfaceofpassivationvisuallytomakesurethatpassivationfilmiscompleteandhasthesamecolor.8.2在回路的最后一个焊缝采用铁氰化钾溶液显蓝测定，变色时间大于30秒钟。Onl