管道酸洗方案

目录content
1.目的purpose
2.适用范围adapted scope
3.编制依据work basis
4.清洗的步骤cleaning proceed
5.清洗后的质量标准the quality standards of cleaning
6.公用设施public service
7.安全管理措施及组织安全管理体系HSE managed measure and the
organized managed chart
8. 施工机具及手段用料construction tools, methods and materials
9. 1、目的purpose
为了确保上海拜耳异氰酸酯和聚醚项目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, 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 People's Republic of China Chemical Industry Standard HG/T2387-92 "chemical cleaning of industrial equipment, quality standards";
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 construction and accepted 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）construction and the 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 construction 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 company《large set chemical cleaning construction standard(including 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 company《the manual of ensuring chemical cleaning quality》
4.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 stainless an carbon in this project, the pipe will be separated each group to clean according to the material and actual condition. The
process 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: stainless pipe DN32,DN48,DN80,totally about 150m. 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, 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。

The purpose of degreasing is to remove all kinds of machine oil, graphite, rust preventing oil and other organics in the system, and make the effective ingredients in the pickling process touch the dirt surface more completely and thoroughly, thus promote the dissolution of metal oxides and dirt, 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%助剂配制而成；the degreased water is made of 6.0-8.0% degrease drug A+1.0-2.0% active surface 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 check one time with the way of titration acid and alkali. Detection into the back to liquid pharmaceutical concentration equivalent 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 electrochemical reaction of soluble material, to remove dirt in the process, while creating conditions for the passivation, pickling is the a key step in 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 system’s
corrosion by ［H+］and ［Fe 3+］.
酸洗药剂采用8.0-10.0%HNO3+（0.5-1.5%）HF+（0.8-1.0%）缓蚀剂LAN-826配制
而成。

The acid water is made of 8.0-10.0%HNO3+（0.5-1.5%）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 water 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 titration system, achieving a balance of acid concentrations, numerically controlled pharmaceutical concentration range of 0.2% inside. Pickling can be concluded. Can also be visual
inspection 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（lan-826）.；the passivation water
is 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 concentration 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。

The purpose is to remove the residual wasted acid water and the solid drop.
When the PH is approach neutralism and the flushing is cleaning, the step
could be finished.
工艺条件 Process conditions
测试项目Test items
4.6清洗废液处理方式 CLEANING WASTE WATER TREATMENT METHOD
✓冲洗废水处理 Disposal of flushing water
a)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 matter 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 6～9, and move to treatment plant.
✓脱脂、酸洗、钝化废液处理 Disposal of pickling and passivation wastewater
a)清洗废液中和至PH达到6～9。

The chemical cleaning wastewater need neutralize PH is 6～9.
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: <the quality standards of chemical cleaning for industrial equipments> (HG/T2387-2007), and Bayer’s specification. 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。

The cleaned metal surface of pipe is clean, almost has no remained oxides and welding ashes, the cleaned surface have no secondary
floating rust and pit corrosion, no metal coarse is precipitated, 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/
㎡·h
No partly corrosion on cleaned metal surface. The corrosion rate should be less than 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 effect can get owner’s 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0.5-1MPa。

Gas:pressure 0.5-1MPa.
电：7.5KW（一台），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 the organized managed chart
7.1安全措施safety precautions
7.1.1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 know well of 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 with the old way of holding by handing and being pickaback.
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；the 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 operator should have the safeguard in the cleaning work, such as exposure, glove
7.1.9设置临时急救设施及药品；Provision of temporary first aid facilities and medicines
7.1.10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 operators to conduct safety education, strengthen the "safety first" mentality, other measures should strictly enforce the China Blue Star Chemical Cleaning Company "cleansing engineering safety operating procedure"
8、施工机具及手段用料construction tools, methods and materials
8.1化学清洗施工机具一览表：
8.2手段用料一览表。