纯化水管线酸洗钝化专项方案.doc

附件20
卫生级管路酸洗钝化方案
Sanitary Pipe Chemical Pickled & Passivation Procedure

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审核/批准

目 录
TABLE OF CONTENTS

1 编制方案根据Basis of scheme compilation 3
2 工作范畴Working scope 3
3 清洗工艺Cleaning process 3
4 清洗过程Cleaning process 5
5 废液解决Waste liquor treatment 9
6 甲方提供条件Condition supplied by the owner 9
7 暂时配管Temporary tubing 10
8 检查与验收Test and accept 10
9 安全 11

1 编制方案根据Basis of scheme compilation
1.1 管道清洗必要性Necessity of piping cleaning
纯化水不锈钢管道在使用前，要进行脱脂、酸洗、钝化和消毒解决，管道才干达到生产使用技术规定。
Before used stainless steel piping for purified water should be degreased，pickled，passivity and disinfected. Only in this way can piping meet technical needs of production and usage.
1.2 《脱脂工程施工及验收规范》HG2-。
Construction and Acceptance Criteria of Industrial Piping
1.3 《工业设备化学清洗质量原则》HG/T2387-
Quality Criteria of Chemical Cleaning for Industrial Equipment
1.4 VWS提供图纸
Drawings supplied by VWS
1.5 管线材质为所有为316L，如有其他材质，清洗前必要阐明。
Material of pipeline is all 316L. Give a description of the material before cleaning if other materials are used.

2 工作范畴Working scope
重要为卫生级不锈钢SS316L管道
Mainly for sanitary SS316L pipe.
1
2
2.1 从纯水制造机到纯水TANK接口前级循环管道；
Pipes from Orion to water tank and pipes of water tank returning to the front tank.
2.2 纯水循环管道；
PW loop distribution Pipes.

3 清洗工艺Cleaning process
3
3.1 采用我公司近年成熟不锈钢管道清洗工艺。
Adopt cleaning process for stainless steel pipe which we are good at.
3.2 管道清洗工艺为：Piping cleaning process is as follows:
暂时配管建立循环回路form circulation——水冲洗water flush——脱脂degrease——水冲洗rinse by water——酸洗pickling,钝化passivation——水冲洗rinse by water——系统恢复system reset
3.3 设备、管线系统内不适当清洗部件：
Components in the equipment and piping that are not suitable to be cleaned
清洗系统中仪表类（一次仪表、二次仪表及仪表传感器）和UV杀菌灯、热互换器（板式及管壳式）对清洗液敏感部件应暂时拆除。
Other components，such as 1st loop instrument，2nd loop instrument and other transmitter，UV，HX (including plate type and tube/shell) that are not in conformity with material and are sensitive to cleaning agent，such as flow meter，conductivity meter，level meter，wiring，tank，etc should be dismantled temporarily.
3.4 管线系统内不参加清洗短管等拆除部件采用浸泡清洗，清洗完毕后经检查合格后用塑料保鲜膜包扎，等管线系统清洗完毕后再安装复位。
All components did not involved on the pipeline to be soaked and cleaned. After cleaned and tested，it must be packed with plastic film. Installed and positioned after pipe clean finished.
3.5 清洗流程Cleaning process

1.
2.
3.
3.1.
3.2.
3.3.
3.4.
3.5.
3.5.1. 所有需要清洗管道用暂时管道连接形成清洗循环系统，采用循环清洗，清洗时建立一种循环回路.
All piping that need cleaning should be connected by temporary piping to form circulation system. Circulating cleaning is used and one loop was formed when proceeding with cleaning.

3.5.2. 清洗流程图

4 清洗过程Cleaning process
所有清洗系统过程是同样。All cleaning system have the same process.
4
4.1 人工解决 Manual handling
4.
4.1.
4.1.1. 管线在清洗前要做全面检查，设备材质和方案中所列要一致。
Pipelines should be inspected in the overall perspective before cleaning and make sure that equipment material is in conformity with that listed in the scheme.
4.1.2. 不参加清洗被隔离仪表阀门等要在清洗前检查确认Isolated instruments and valves that are not cleaned should be checked before cleaning。
4.1.3. 测试样品必要包括两个新焊，未清洗焊缝。一种安装在将要清洗管路中，此外一种放在化学清洗罐内;.

4.2 水冲洗：水冲洗及试压目在除去管线内表面积灰、泥沙、脱落金属氧化物及其他疏松污垢，并在模仿清洗状态下对暂时清洗回路进行泄漏检查。
Rinse with water. Rinse and pressure test aim to remove ashes，mud and shed metallic oxide and other loose dirt on the surface of pipelines and proceed with leak test on temporary cleaning loop under the circumstances of cleaning stimulation.
用纯化水（氯离子不大于0.1ppM）进行冲洗，冲洗时控制进出水平衡。冲洗同步检查清洗循环系统与否有泄漏等状况发生，如果有，在清洗剂添加前要解决好。
Rinse with purified water (chlorine ion is less than 0.1ppM). In rinse process control the balance between incoming and outgoing water and check if circulating system leaks. If so，do it well before adding cleaning agent.

4.3 脱脂：脱脂解决目系统内表面在制作、安装、过程中产生油脂，使酸洗液能完全，彻底地和系统内表面接触，从而使清洗彻底，钝化膜完整；
Degrease. It aims to degrease the oil produced in the fabrication，installation of inner surface of system to make pickling agent get in full contact with inner surface system. Therefore cleaning can be finished fully and passivation membrane is in complete situation.
4.2.
4.3.
4.3.1. 操作环节，系统加入纯化水（氯离子不大于0.1ppM）至预定液位，开始循环，并加入碱洗药剂。
Procedure. Inject purified water (chlorine ion is less than 0.1ppM) into the system and begin the circulation. And add alkaline cleaning medicament for stainless steel and degreasing finishes.
4.3.2. 工艺条件：Process
温度 temperature 常温normal temperature
循环时间 circulating time 2小时hours
循环时间可依照天气、管道复杂状况恰当延长或缩短。
Circulating time can be lengthened or shortened according to the weather and piping.
4.3.3. 脱脂药剂：Degreasing medicament
序号
No
名称
Name
1
氢氧化钠直到其浓度为2%-3%

4.3.4. 测试项目：Items to be tested
PH 1次/半小时 once/half hour
脱脂液PH规定维持在12以上，当PH不大于12时应添加氢氧化钠。
PH of Degreasing agent to be kept as above 12 and sufficient degreasing agent to be added.
PH测试使用PH试纸
PH checked with PH test paper

4.4 水力冲洗：水力冲洗目是除去脱脂后脱落污物，并将系统表面残留脱脂液冲洗干净。
Water rinse to get rid of shed ordure and flush remaining degreasing agent on system surface clean.
4.4.
4.4.1. 操作环节，排尽系统内脱脂液，用大量水冲洗。
Operation procedure. Drain degreasing solution in the system and flush the system with enough water.
4.4.2. 测试项目，用视觉观测冲洗水至透明无微粒，测定PH不大于9。
Items to be tested. Check flush water to be transparent with no particulate visually and make sure PH value less than 9.
PH 2次/半小时twice/ half hour
PH测试使用PH试纸，当PH不大于等于9时水冲洗完毕。
PH checked with PH test paper and water flush finished when PH<9.

4.5 酸洗：酸洗目是运用酸洗液将金属表面铁锈氧化物等污垢进行化学和电化学反映，生成可溶性物质，并运用酸洗液冲刷作用除去污垢。
Pickling. Pickling aims to make dirt like rusted oxide on the surface of metal proceed with chemical and electromechanical reaction to produce dissoluble material and get rid of dirt with pickling solution.
4.5.
4.5.1. 操作环节，排净系统水冲洗残液后，随后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。清洗过程中定期排污排空。
Operation procedure. After remaining rinse solution is drained away，inject a certain amount of water into the system to a certain level for circulation. Add special pickling medicament for stainless steel into it. Then inject a certain water to control level. Blow down the waste periodically during cleaning.
4.5.2. 工艺条件：Process situation
清洗温度 cleaning temperature 常温normal temperature
循环时间 circulating time 2小时hours
4.5.3. 酸洗钝化药剂：
序号
No
名称
Name
1
柠檬酸，保证浓度在10%~15%

4.5.4. 测试项目：Items to be test
pH值 PH value 1次/半小时twice/half hour
酸洗液PH规定不大于等于1，当PH不不大于１时应添加柠檬酸，保证浓度在10%~15%。
Picked chemical PH less than 1 and picked chemical to be added incase PH is higher than 1.
PH测试使用PH试纸
PH checked with PH test paper

4.6 水冲洗：钝化完毕后水冲洗是为了把残留钝化液除去。
Water rinse. Water rinse after finishing passivation is to get rid of remaining passivation solution.
4.6.
4.6.1. 钝化结束后，排尽钝化液洗液，用纯化水（氯离子不大于0.1ppM）进行冲洗，除去残留钝化液，当PH直接近中性Ph>6，电导率差不大于0.5μs/cm，即可结束。
After finishing passivation，drain away solution for passivation and flush with purified water (chlorine icon is less than 0.1ppM) to remove remaining passivation solution. When PH is close to the neutralization (pH>6)，difference of conductivity less than 1μs/cm passivation finishes.
4.6.2. 工艺条件Process condition
清洗温度cleaning temperature 常温 normal temperature
4.6.3. 测试项目：Items to be tested
PH 2次/半小时twice/half hour
电导率 conductivity 2次/半小时twice/half hour
PH测试使用PH试纸
PH test by PH test paper.
使用电导率仪测定电导率
Cond tested by cond. Meter.

4.7 系统恢复，清洗完毕后将系统恢复原样。
System reset. Get the system back after finishing cleaning.

4.8 如果系统长时间不投入使用，建议用氮气封存。
If the system is not put into use for a long time，nitrogen is suggested for sealing.

5 废液解决Waste liquor treatment
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5.1 各清洗过程中冲洗水，未添加清洗剂，可以直接排放。
Flush water without cleaning additive during cleaning can be discharged directly.
5.2 酸洗液废液，钝化液废液，用槽罐车把废水运送到废水解决厂解决排放。
Waste liquor of pickling solution and greasing solution should be delivering with tank car to waste water treating plant for handling and discharging.

6 甲方提供条件Condition supplied by the owner
甲方负责提供如下公用设施：
The following utilities are provided by the owner.
6
6.1 水：全程采用纯化水，纯化水规定氯离子不大于0.1ppM，使用ORION纯化水.
Purified water is used through the system and purified water should include less than 0.1ppM chlorine icon. Orion will provide the purified water for chemical pickled and passivation..
6.2 电源(清洗时使用纯化水泵)。
Power supply. Purified water pump is used when cleaning.
6.3 干燥无油压缩空气或氮气，0.5-1 MPa。
Dry compressed air or nitrogen with no oil of 0.5-1 MPa.

7 暂时配管Temporary tubing
7
7.1 暂时配管是指将清洗系统中管道连接起来，形成清洗循环回路，清洗完毕后需要拆除管道和设施。
Temporary tubing is the piping and facility that need be dismantled after cleaning Connect piping in the cleaning system to form circulating loop.
7.2 暂时配管用软塑料管。Temporary tubing adopts soft plastic tube.

8 检查与验收Test and accept
8
8.1 钝化表面目测，钝化膜完整，颜色一致。
Check the surface of passivation visually to make sure that passivation film is complete and has the same color.
8.2 在回路最后一种焊缝采用铁氰化钾溶液显蓝测定，变色时间不不大于30秒钟。
On last welding seam，Adopt potassium ferrocyanide for blue indication ameasuring and color changes for more than 30 minutes.
(蓝点实验 blue indication test：
用1克铁氰化钾K3[Fe(CN6)]加3毫升(65%_85%)硝酸HNO3和100毫升水配制成溶液(宜现用现配)。然后用滤纸浸渍溶液后,贴附于待测表面或直接将溶液涂、滴于待测表面,30秒内观测表面显现蓝点状况,有蓝点为不合格。)
Blue indication test solution is mixed with 1g K3[Fe(CN6)]，3ml 65%_85% HNO3 and 100ml water. Use filter paper to soak with this solution and stick it to the material surface or drop this solution on the surface of material to be tested. It is disqualified if there is blue point appeared within 30seconds on the surface of material.

8.3 清洗完毕后提供“清洗过程报告”。
After cleaning，report of cleaning process should be provided.

9 安全
重要为卫生级不锈钢SS316L管道.
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10
10.1 在进行清洗工作时，咱们必要要得到工作允许；
10.2 在和化学产品关于工作时，只有具备有效个人防护（脸部保护，防护衣，防护鞋等）人才容许参加；
10.3 现场附近需要设立应急冲洗水点，可以冲洗身体和眼睛
10.4 工作区域和危险位置必要拉警戒线防止未授权和没有保护人员进入;
10.5 将在整个工作区域/房间悬挂境界标记;
10.6 持续监控敞开容器;
10.7 化学品必要存储在指定安全区域，工作结束后废液必要及时从现场移除;
10.8 氢氧化钠，柠檬酸酸材料安全技术阐明书要放在现场