D6潔凈管道清洗、鈍化規(guī)范.doc

潔凈管道清洗、鈍化規(guī)程Sanitary Pipe Cleaning and Passivation Specifications1、概述Summary(1)、目的：通過該程序和滅菌程序，使?jié)崈艄艿滥軌蜻_到符合輸送純水、注射用水、純蒸汽及其它物料的要求。Intents: Through this procedure and sterilization procedure, the sanitary pipes can conform to the requirements of transporting PW, WFI, pure steam and other materials.、堿洗：清洗管道內壁的油污、雜物及其它有機物。Alkali cleaning: remove the grease, mess and other organism from the inner piping wall、酸洗：將管道內壁焊縫處的焊瘤、毛刺等洗除。Pickling: remove the burr and welding bulge from the welding seam of the inner piping wall、鈍化：將管道內壁的凸出、尖出洗平或洗鈍。Passivation: level or passivate the bulge and spine on the inner piping wall(2)、要求：經過酸洗、鈍化的潔凈管道，在管路滅菌后對所輸送的介質不產生新的污染。Requirement: the passivated and pickled sanitary pipes dont make recontamination to the transporting media after sterilization.2、方法Methods(1)、原理：通過強酸（一般為HNO3）對金屬的強氧化性、強腐蝕性對管路進行酸洗、鈍化。Principle: pickle and passivate the pipes through strong oxidation and corrosion of strong acid (generally HNO3) to metal(2)、配制：（詳見附表）Compounding method; (for details, see the attached form)、堿洗：10%的NaOH（濃度為98%）和90%的純水的堿溶液對管路循環(huán)沖洗。Alkali cleaning: circularly flush the loop with alkali solution of 10% NaOH（concentration:98%）and 90% PW、酸洗：50%的酸其中HNO3（濃度為65%68%）占75%，HF（濃度為40%）占25%和50%的純水的酸溶液對管路循環(huán)沖洗。Pickling: circularly flush the loop with acid solution of 50% acid among it 75% is HNO3（concentration between 65%68%）and 25% is HF（concentration 40%） and 50% PW.、鈍化：20%的HNO3（濃度為65%68%）和80%的純水的酸溶液對管路循環(huán)沖洗。Passivation: circularly flush the loop with acid solution of 20% HNO3（concentration 65%68%）and 80% PW3、準備工作Preparations(1)、材料準備：事先應先按管路的長度和容器的容積計算出所需酸堿的容積，然后根據配制比例，準備好所需的酸堿量。Material preparation: calculate in advance the acid and alkali needed according to the piping length and container capacity. Prepare certain needed quantities of acid and alkali according to the compounding proportion. 若無處理排放酸的設施，最好應增加用于中和酸的NaOH。Use NaOH to neutralize the acid if no facilities are available for disposing of and discharging the acid. 酸最好是桶裝酸，純度為工業(yè)用純度就可。Acid in bucket is preferred. Industry purity is enough. 堿可用袋裝片堿。純度為工業(yè)用純度就可。Alkali tablets in bag are acceptable. Industry purity is enough.(2)、計量、檢查工具的準備：酸洗、鈍化的容器最好為帶有刻度的容器，便于計量溶液的體積（重量）。Preparation of dosing and inspecting tools: vessels with scales are preferred for pickling and passivation because its convenient to measure the solution volume (weight). 固體堿稱量可用桿秤、彈簧秤稱量。Steelyard and spring balance can be used to weigh the solid alkali. 溫度表、壓力表、試紙等。Thermometer, pressure gauge, test paper, etc.(3)、防護用品的準備：安全帽、防酸手套、防酸面罩、耐酸圍裙及其它勞保用品。Preparation of safety apparatus: safety helmet, antacid gloves, antacid veil, antacid apron and other labor protection apparatus. 為防止酸、堿濺到人體、皮膚上，最好應準備部分醋酸和小蘇打（NaHCO3）溶液和干紗布。同時還應準備創(chuàng)口貼、白藥、脫脂紗布、膠布等常用藥品。Prepare some acetic acid, saleratus （NaHCO3）solution and dry gauze to prevent acid and alkali spattering to human body and skins. Prepare some common drugs as well, such as wound protector, Baiyao, degreased gauze, rubberized cloth, etc.(4)、設備的準備：耐酸堿循環(huán)泵，閥門、耐酸堿的橡膠軟管，喉箍，鉛絲，盲板、墊片、卡箍、卡箍長接頭，以及用于封堵拆除儀表后的接口堵頭。Equipment preparation: acid and alkali resistant pump, valve, acid and alkali resistant rubber hose, lead thread, blind plate, gasket, clamp, clamp liner long and joint block for sealing after the gauges are removed. 氬弧焊機、電源線、氬氣以及防護面罩、焊絲等。Argon Arc Weld Machine, power supply line, argon, safety veil and welding rod, etc(5)、其它工具的準備：扳手、手虎鉗、螺絲刀、電筆、手電筒、耐酸的攪拌棒、水桶等。Other tool preparation: spanner, pliers, screwdriver, electroprobe, electric torch, acid resistant muddler, bucket, etc. 若檢查部位較多，如多層建筑；或制水間離用水點距離較遠，應配備對講機，以便即時通知，更好的協(xié)調工作。If the locations needing check are too many, like multi-layer building, or the water generation room is too far away from points of using, interphones should be used for timely notification and better communications.以上所有材料、設備、工具均應完好，可直接投入使用。All the above materials, equipments and tools are perfect and can be put into use directly.4、操作過程Operation process(1)、水沖洗：Water flushing用純水經循環(huán)泵對管路進行循環(huán)沖洗，邊沖洗，邊排放。時間不得低于20分鐘。Purified water circularly flushes the loop through circulating pump. Drain the water at the same time it is flushing. Duration should be no less than 20 minutes.(2)、堿洗準備：Preparation for alkali cleaning先將裝堿液的容器與循環(huán)泵及管路系統(tǒng)連接起來，在末端接上軟管至堿液容器，并保證連接和容器嚴密不漏。確認后先向容器中放入已計算好用量的純水，再慢慢放入已計算好用量的固體堿。并用攪拌棒充分攪拌均勻。接通水泵電源，斷開控制開關，準備堿洗。Firstly connect the alkali solution vessel with circulating pump and piping system by a hose between the vessel and pipe end. After confirming the vessel and connection are tight and have no leaks, infuse stated quantities of PW into the vessel. Then slowly put in stated quantities of solid alkali and mix them equally with a mix rod. Connect power supply for the pump, turn off the switch, and get ready for alkali washing.攪拌人員應戴好防酸堿面罩，防止對人員造成傷害。Mixing person shall wear acid and alkali resistant veil in order not to bring damages to personnel.裝堿的容器應完好，無任何滲漏，與管道接口處連接良好。The alkali solution vessel shall be in good conditions and have no leakages. The joint should be well connected.(3)、堿洗：Alkali cleaning合上控制開關，用循環(huán)泵抽堿溶液進管路系統(tǒng)，對管路循環(huán)沖洗，時間大約為30分鐘。在堿洗過程中，應有專人檢查（檢查方法：用試紙與焊點處接觸，若無變色則說明無泄露）每一焊點，發(fā)現(xiàn)漏點，應立即通知看泵人員停泵，并在漏點附近的用水點放空堿液，并對漏點進行補焊等相關處理。處理后方可繼續(xù)進行堿洗，對流到地面、吊頂上的堿液應用干布擦拭干凈。Switch on the controller and flush the piping loop with alkali solution through circulating pump for about 30 minutes. During this period, there shall be person specially in charge of checking (method: contact the welding point with test paper. No discoloration means no leak) each welding point. If any leaking point is found, notify the pump monitoring person to stop the pump immediately, drain the alkali solution at the using points nearby the leaking point, and process certain treatment like rewelding to the leaking point. Until after treatment can alkali cleaning continue, wipe off the alkali solution water flowed on the floor or suspended ceiling with dry cloth.(4)、水沖洗：Water flushing用純水經循環(huán)泵對管路進行循環(huán)沖洗，邊沖洗，邊排放；直至排放的水為中性為止。Purified water circularly flushes the loop through circulating pump. Drain the water at the same time it is flushing until the draining water is neutral.對循環(huán)后的堿溶液，應用另外的容器暫存，以用于與酸中和排放。Use a vessel in addition to store the circulated alkali solution so that it can be drained after neutralization with acid.(5)、酸洗準備：Preparation for pickling先將裝酸的容器與循環(huán)泵及管路系統(tǒng)連接起來，在末端接上軟管至酸溶液容器，并保證連接和容器嚴密不漏。確認后先向容器中放入已計算好用量的純水，再慢慢放入已計算好用量的酸。并用攪拌棒充分攪拌均勻。接通水泵電源，斷開控制開關，準備試壓。First connect the acid solution vessel with circulating pump and piping system by a hose connecting the vessel and pipe end. After confirming the vessel and connection are tight and have no leakages, pour stated quantities of PW into the vessel. Then slowly put in stated quantities of acid and mix them equally with a mix rod. Connect power supply for the pump, turn off the switch, and get ready for pickling.攪拌人員應戴好防酸堿面罩，防止對人員造成傷害。Mixing person shall wear acid and alkali resistant veil in order not to bring damages to personnel.裝酸的容器應完好，無任何滲漏，與管道接口處連接良好。如可能也可將容器放到室外。The acid solution vessel shall be in good conditions and have no leakages. The joint shall be well connected. Laying the vessel outdoor is acceptable.若容器滲漏時，可用清水對準滲漏點不停的沖洗，直至酸洗完成。If vessel leaks, flush the leaking point ceaselessly with clear water until pickling accomplished.(6)、酸洗：Pickling合上控制開關，用循環(huán)泵抽酸溶液進管路系統(tǒng)，對管路循環(huán)沖洗，時間大約為60分鐘。在酸洗過程中，應有專人檢查（檢查方法：用試紙與焊點處接觸，若無變色則說明無泄露）每一焊點，發(fā)現(xiàn)漏點，應立即通知看泵人員停泵，并在漏點附近的用水點放空酸液后，用膠帶紙纏繞包扎漏點，并在漏點下方放上水桶，以便接住流出的酸液（若無法用桶接水，應在漏點下方墊上浸過稀堿液的抹布）。將循環(huán)泵接通純水對管路進行水沖洗，待管路系統(tǒng)中的酸液全部排放后，方可對漏點進行補焊等相關處理。處理后方可繼續(xù)進行酸洗，對流到地面、吊頂上的酸液應用干布擦拭干凈，對流到縫隙處的酸，應用稀堿液進行中和后，在用干布擦凈。Switch on the controller and flush the piping loop with acid solution through circulating pump for about 60 minutes. During this period, there shall be person specially in charge of checking (method: contact the welding point with test paper. No discoloration means no leakage) each welding point. If any leaking point is found, notify the pump monitoring person to stop the pump immediately. After draining the acid solution at the using points nearby the leaking point, rotate bandage around the leaking point and put a bucket under the leaking point to collect the leaking acid solution (if bucket is not available, replace it with weak alkali solution soaked duster cloth). Switch on the circulating pump and flush the loop with PW. Process certain treatment like rewelding on the leaking point until all the acid solution is drained from the loop. Only after treatment could pickling continue, wipe off the acid solution water flowed on the ground or suspended ceiling with dry cloth. To the acid flowing to the cracks, neutralize them with weak alkali solution before wiping them off.(7)、水沖洗：Water Flushing用純水經循環(huán)泵對管路進行循環(huán)沖洗，邊沖洗，邊排放；直至排放的水為中性為止。Purified water circularly flushes the loop through circulating pump. Drain the water at the same time it is flushing until the draining water is neutral.(8)、鈍化準備：Preparation for Passivation先將裝酸的容器與循環(huán)泵及管路系統(tǒng)連接起來，在末端接上軟管至酸溶液容器，并保證連接和容器嚴密不漏。確認后先向容器中放入已計算好用量的純水，再慢慢放入已計算好用量的酸。并用攪拌棒充分攪拌均勻。接通水泵電源，斷開控制開關，準備試壓。First connect the acid solution vessel with circulating pump and piping system by a hose connecting the vessel of acid solution and pipe end. After confirming the vessel and connection are tight and have no leakages, pour stated quantities of PW into the vessel. Then slowly put in stated quantities of acid and mix them equally with a mix rod. Connect power supply to the pump, turn off the switch, and get ready for pickling.(9)、鈍化：Passivation合上控制開關，用循環(huán)泵抽酸溶液進管路系統(tǒng)，對管路循環(huán)沖洗，時間大約為120分鐘。在鈍化過程中，應有專人檢查（檢查方法：用試紙與焊點處接觸，若無變色則說明無泄露）每一焊點，發(fā)現(xiàn)漏點，應立即通知看泵人員停泵，并在漏點附近的用水點放空酸液后，用膠帶紙纏繞包扎漏點，并在漏點下方放上水桶，以便接住流出的酸液（若無法用桶接水，應在漏點下方墊上浸過稀堿液的抹布）。將循環(huán)泵接通純水對管路進行水沖洗，待管路系統(tǒng)中的酸液全部排放后，方可對漏點進行補焊等相關處理。處理后方可繼續(xù)進行鈍化，對流到地面、吊頂上的酸液應用干布擦拭干凈，對流到縫隙處的酸，應用稀堿液進行中和后，在用干布擦凈。Switch on the controller and flush the piping loop with acid solution through circulating pump for about 120 minutes. During this period, there shall be person specially in charge of checking (method: contact the welding point with test paper. No discoloration means no leakage) each welding point. If any leaking point is found, notify the pump monitoring person to stop the pump immediately. After draining the acid solution at the using points nearby the leaking point, rotate bandage around the leaking point and put a bucket under the leaking point to collect the leaking acid solution (if bucket is not available, replace it with weak alkali solution soaked duster cloth). Switch on the circulating pump and flush the loop with PW. Process certain treatment like rewelding to the leaking point until all the acid solution is drained from the loop. Only after treatment could pickling continue, wipe off the acid solution water flowed on the ground or suspended ceiling with dry cloth. To the acid flowing to the cracks, neutralize them with weak alkali solution before wiping them off.(10)、水沖洗：Water Flushing用純水經循環(huán)泵對管路進行循環(huán)沖洗，邊沖洗，邊排放；直至排放的水為中性為止。Purified water circularly flushes the loop through circulating pump. Drain the water at the same time it is flushing until the draining water is neutral.(11)、廢液排放：Wastewater discharge將用完后的廢酸、廢堿應中和至中性或近似中性后方可直接排放。另有處理的除外。Neutralize the waste acid and alkali to neutralization or almost neutralization prior to discharge unless they are treated in other ways.5、注意點Points need to pay attention to(1)、堿洗、酸洗、鈍化時每個檢查人員應以高度的責任心仔細檢查每一焊點，堅決不放過每一個可能漏點。When alkali cleaning, pickling and passivation are carried out, each inspector shall check each welded point with high responsibility and do not let pass each possible leaking point.(2)、試壓、堿洗、酸洗、鈍化時每個檢查人員都應帶好水桶、抹布和試紙等物；堿洗、酸洗、鈍化時還應帶好耐酸手套、防酸面罩等防護用品，吊頂內檢查人員還應戴好安全帽，帶上照明器材，保證檢查時有足夠的照度。When operating pressure test, alkali cleaning, pickling and passivation, each inspector shall bring bucket, duster cloth and test paper; safety apparatus shall be put on such as antacid gloves and antacid veil when operating alkali cleaning, pickling and passivation. Inspectors on the suspended ceiling shall wear safety helmet and bring lighting facilities to ensure enough light.6、防護要點Safety points(1)、人員防護： Personnel Safety、配制酸堿液人員、檢查人員等相關人員均應戴好防酸手套、防酸面罩及防酸工作服等。Alkali and acid compounding personnel, inspector and relative person shall wear antacid gloves, antacid veil and antacid uniform.、發(fā)生事故時，第一要確保人員的安全。Protect human safety firstly once accident happens.、若堿液濺到皮膚上應立即用干布擦凈，然后用醋酸涂于濺落處片刻，最后用清水沖洗干凈。If alkali spatters on skin, wipe it off immediately by dry cloth, paint acetic acid on the spattered area for a while, then clean it by clean water.、若酸液濺到皮膚上應立即用干布擦凈，然后用小蘇打溶液涂于濺落處片刻，最后用清水沖洗干凈。If acid spatters on skin, wipe it off by dry cloth immediately, paint saleratus on the spattered area for a while, then clean it by clean water.、嚴禁直接用手或其它裸露皮膚直接接觸酸液、堿液，用抹布擦拭酸堿液時必須帶好防酸手套和防酸面罩。Touching the alkali and acid directly with hands or other exposed skin is strictly forbidden. Wear the antacid gloves and antacid veil while wiping the acid and alkali solution with duster cloth.、配制酸堿溶液時，應緩慢地將堿、酸沿容器壁流進水中，嚴禁直接將酸堿溶液倒入水中，以防濺起酸堿液。特別嚴禁將堿（或酸）直接倒入酸（或堿）中。Slowly pour the alkali and acid and let it flow to the water along the inner wall while compounding the alkali or acid solution. Directly pour the acid or alkali into water is forbidden for preventing spatter any solution. Especially forbid pouring alkali (or acid) directly into acid (or alkali).2、其它防護： Other safety measures、對可能濺落到酸堿液的設備、管道、儀表、地面、墻面、吊頂、隔斷應盡可能事先用塑料紙包扎保護，對設備、管道上的儀表也可事先拆除。If