管道清洗方案(Rev.B)

1、 張家港保稅區(qū)利柏特鋼制品有限公司張家港保稅區(qū)利柏特鋼制品有限公司Zhangjiagang FTZ Libaite Steel Products Co., Ltd.中國中國 江蘇省江蘇省 張家港市張家港市 張家港保稅區(qū)張家港保稅區(qū)Zhangjiagang Free Trade Zone, Zhangjiagang, Jiangsu, P.R.ChinaPiping Cleaning Procedure管管 道道 清清 洗洗 方方 案案(REV. B)B第二次發(fā)布2nd Issue王忠建A第一次發(fā)布First Issue王忠建版本號Rev簽發(fā)或版本說明Issue or Revision Desc

2、ription編制人Prepared by日期Date審核人Reviewed by日期Date批準人Approved by日期DateCTI日期Date張家港保稅區(qū)利柏特鋼制品有限公司Zhangjiagang FTZ Libaite Steel Products Co., Ltd. Page 2 of 11SO2/CO2 CAPTURE DEMO PLANT FABRICATION AND ASSEMBLY OF MODULES目 錄Table of Contents1、工作范圍：Scope.32、編制依據：Reference .33、表面清潔度：Surface Cleanliness .34

3、、人員培訓：Personnel Training.45、污染物鑒定：Contaminant Identification.46、清洗范圍 Cleaning Scope .57、清洗程序（SO）：Oxygen Cleaning Procedure (SO).58、表面清潔度檢驗、驗收方法：Inspection & Acceptance Methods for Surface Cleanliness.79、酸堿濃度的定期檢測和維持：Periodical Inspection & Maintenance of Acid-base Concentration.810、管道焊口清洗 Cl

4、eaning of Pipe Welds.811、廢液溶解：Waste Solution Treatment .912、安全保護：Security.913、溶液酸堿濃度檢測方法 PH Concentration Inspection Methods for Cleaning Solution -10張家港保稅區(qū)利柏特鋼制品有限公司Zhangjiagang FTZ Libaite Steel Products Co., Ltd. Page 3 of 11SO2/CO2 CAPTURE DEMO PLANT FABRICATION AND ASSEMBLY OF MODULES1工作范圍：工作范圍

5、：Scope為規(guī)范 Cansolv 公司 SO2/CO2 收集模塊管道清潔施工流程，明確工藝要求，編制此方案。This procedure is proposed to standardize piping cleaning process and define relevant process requirements for Cansolv SO2/CO2 capture System Project.2編制依據：編制依據：ReferenceASTM A380-06 不銹鋼部件設備系統(tǒng)的清潔&除垢&鈍化 Standard Practice for Cleaning, Des

6、caling, and Passivation of Stainless Steel Parts, Equipment, and Systems3表面清潔度：表面清潔度：Surface Cleanliness3.1所有應清潔的表面在明亮的燈光及紫外線照射下，不得有可見的污染物。Any visible contaminant is not allowed to appear on cleared surface under bright light or ultraviolet radiation.3.2所有清潔表面，油脂含量應小于 100mg/m2,用波長 320380um 功率為w 的紫光照

7、射下時,表面不得有油脂熒光。For all clear surfaces, grease content shall be less than 100mg/m2. Grease fluorescence shall not appear while irradiating with ultraviolet of 320380um wavelength and 100w power.3.3用于清洗的設備和工具要保持干凈，并與其它工具分開放置，所有工具在每次使用前徹底清洗干凈，這也包括部件最后清潔使用的實驗設備。清洗用的特殊工具、材料、測試儀器在使用前必須徹底清潔。所用的工具包括：測試儀器、吊裝工

8、具、吹掃設備、輕便手動工具。The equipments and tools for oxygen cleaning must keep clean and separated from others; all tools shall be cleared thoroughly prior to application, including test apparatus for components final cleaning. Special tools, materials, and test instruments for cleaning must be cleared thorou

9、ghly. The tools to be applied include: test instruments, lifting tools, blowing equipments and portable hand tools.3.4在使用前用無毛絨干凈布沾上異丙醇擦拭，確保它們無油、灰塵、碳氫化合物、油漆等。用黑光燈檢驗無熒光反應。工作平臺應用無油的清潔的聚乙烯薄膜鋪墊，覆蓋好。用于清洗的清洗劑應保持潔凈、有效，不可反復循環(huán)使用。清潔好的工具用一個干凈的工具箱裝好，不允許和其它工具混裝。Wipe with clean, lint-free cloth wet by isopropyl al

10、cohol prior to using to ensure no grease, dust, hydrocarbon, paint, etc.; no fluorescence appeared while Wood lamp testing. Clean gaseous rust protection paper or polyethylene film shall be put and covered on work platform. Detergent for cleaning shall be clean and efficient, recycled using is not a

11、llowed. Cleaned tools shall be packed in a clean tool-box to avoid mixing with others.3.5我們使用的設備包括：Equipments applied including:噴砂車間一個 One sandblasting workshop酸洗槽一個 One pickling tank 7300MM 長 length 950MM 寬 width 900MM 高 height脫脂槽一個 One degreasing tank 7300MM 長 length 2300MM 寬 width 900MM 高 height高

12、壓潔凈水槍 流量 200 升/小時，壓力為 8 公斤/厘米 3 High-pressure squirt gun with flow rate of 200L/hour and pressure of 8kg/cm3張家港保稅區(qū)利柏特鋼制品有限公司Zhangjiagang FTZ Libaite Steel Products Co., Ltd. Page 4 of 11SO2/CO2 CAPTURE DEMO PLANT FABRICATION AND ASSEMBLY OF MODULES行車或汽車吊（5T）一臺 One traveling crane or truck crane (5t)

13、空氣壓縮機一臺 流量 10m3/min，壓力為 8 公斤/厘米One air compressor with flow rate of 10m3/second and pressure of 8kg/cm3清洗場地：清洗場地分為清洗區(qū)和待清洗區(qū) 2 個區(qū)，該區(qū)域要求明確標識隔離Cleaning site: it was divided to 2 isolated areas of cleaning and ready-for-cleaning with clear marks.4人員培訓：人員培訓：Personnel Training 所有從事清洗的人員都必須經過嚴格的培訓，讓他們了解清洗程序

14、，清潔設備，用于清洗的清潔劑的使用方法以及清洗的安全常識。公司必須提供指定的安全手冊給這些職員。建立各種必要的安全設施設備及個人防護用品，所有施工人員應了解各種工作存在的潛在危險，在施工過程中，施工人員正確配帶 PPE。All personnel implement cleaning must be trained strictly to know the cleaning process, equipment, cleaning agent application methods and safety common sense of cleaning. The company shall p

15、rovide specified safety manual, apparatus and PPE; during construction, all personnel must understand any potential risks, properly wear PPE and take with safety manual. 從事氧清潔工作的工人應接受全面培訓，要意識到不充分不適當的清潔方法會產生嚴重的后果。All workers take charge of oxygen cleaning shall be trained overall to understand insuff

16、icient and unsuitable cleaning method will cause serious aftermath. 工人應穿上特定的工作服，工作時手必須戴干凈防酸手套。為防止清潔液或清洗劑濺入眼睛，工作時應戴上有側面罩的安全眼睛鏡和面罩。During cleaning, the workers must wear special clothes, whose hands must be wear clean, acid-protection gloves; safety goggles with side covers shall be wore to avoid clea

17、ning solution or agent splashed into eyes. 盡可能避免身體暴露部位接觸清洗液，清洗時應戴上橡皮手套。所有氧化物溶劑吸入一定量時對人體有害，因此，當用氯化物進行清洗時應在室外或通風良好的條件下進行，或使用適當的呼吸器（如氧氣面罩） 。Minimize the contact between exposed parts of body and cleaning solution, rubber gloves shall be applied. All oxide solutions are harmful for body, so cleaning wit

18、h chlorides shall be executed outside or well-ventilated, or wear suitable breather (such as oxygen mask). 所有的裝置，工具，化學物質要分開安全存放以保證安全，有毒，易燃的物質要有明顯的危險標識。All device, tools and chemicals shall be stored separately to ensure their safety; toxic and flammable materials shall be marked clearly.5 污染物鑒定：污染物鑒

19、定：Contaminant Identification原材料表面攜帶的污染物，如油脂，碳氫化合物，防銹劑等應用黑光燈檢測，是否有熒光反應。The contaminants on materials such as grease, hydrocarbon or anti-rust agent shall be inspected with Wood lamp if they appear fluorescence.加工過程中觸及的污染物。 （如用于機械切割的冷卻潤滑油等，如熒光反應，應在此類潤滑油中添加顯熒光劑。 ）Contaminant produced during machining.

20、(such as add fluorescent 張家港保稅區(qū)利柏特鋼制品有限公司Zhangjiagang FTZ Libaite Steel Products Co., Ltd. Page 5 of 11SO2/CO2 CAPTURE DEMO PLANT FABRICATION AND ASSEMBLY OF MODULESdeveloper into cooling lubricant for mechanical cutting)6清洗范圍清洗范圍 Cleaning Scope管道材料脫脂、鈍化。Piping Material Degreasing & Passivating由

21、于是新裝置，管道及系統(tǒng)不需要進行除垢處理 Piping and system are not required to receive descaling as they are all new.7清洗程序（清洗程序（SO）：）：Oxygen Cleaning Procedure (SO)7.1 模塊管道制造程序大體可分為：Fabricating procedure for module pipes shall be divided into: 7.2 材料的接受和檢驗（材料合格證或質保書）Material acceptance & inspection (material certif

22、icate or QA document) 班組領料 Material issuance 所有的管件進行清洗 Cleaning 下料 Cutting 管段組對（管段不超過兩個彎頭）Spools fit-up (each spool shall not exceed 2 elbows) 管段徹底清洗（管段按要求先做 NDE）Cleaning spools thoroughly (NDE first as per related requirements) 標識移植 Marking transplant 管道現場安裝（注意保持管段內部清潔度）Installation on site (pay sp

23、ecial attention to keep the inside cleanliness of pipes) 焊口檢查（PT/RT）Welds testing 管道試壓 Pressure Testing 驗收 Acceptance7.3 清洗的過程包括原材料的清洗，組裝過程中的清洗和保護。對于碳鋼材料的清洗我們采用噴砂除銹、脫脂的方法。對于不銹鋼材料的清洗我們采用槽浸法，安裝過程中，材料受到 2 次污染我們采用溶劑，異丙醇擦拭。The cleaning including the cleaning and protection for original materials and asse

24、mbling process. Sandblasting and degreasing will be applied for CS material and, tank soaking for SS material. During installation, solution or isopropyl alcohol wiping will be applied for secondary pollution.7.4 為了徹底地清潔管子與管件的主要污染物（油，灰塵，微粒，潮濕氣體等） ，我們必須根據規(guī)范。In order to clean the main contaminants (gr

25、ease, dust, particle moisture) of pipes and fittings thoroughly, we must fully follow the specifications associated.對碳鋼管道外部采用噴砂處理（同時內壁保持清潔） 。Outer of CS pipes shall be subject to sandblasting (the inner wall should be kept clean meanwhile).不銹鋼采用化學溶液進行清洗，配制所需要的化學溶劑，管道和管件采用槽浸法，主要針對于 1.5m 直徑以下的管道和管件的清洗

26、。, The SS pipes shall be cleaned by means of chemical solutions: firstly, prepare the solution as required, and then adopt soaking for pipes and fittings with diameter less than 1.5m.7.5 碳鋼管的清洗 CS Pipes Cleaning噴砂處理應在適宜的溫度條件和濕度下進行（溫度高于 10 度，相對濕度低于 70%）Sandblasting shall be executed in suitable tempe

27、rature and humidity (temperature more than 10 and relative humidity less than 70%).對灰色金屬采用噴砂處理是對清掃碳鋼件的最佳方法。除了用無油、干燥的壓縮空氣吹掃、拖帚清掃徹底清除顆粒外,不必再用另外的清掃方法。因此對于碳鋼管道均采用外噴沙的方式張家港保稅區(qū)利柏特鋼制品有限公司Zhangjiagang FTZ Libaite Steel Products Co., Ltd. Page 6 of 11SO2/CO2 CAPTURE DEMO PLANT FABRICATION AND ASSEMBLY OF MOD

28、ULES進行處理，管道噴砂應達到 Sa2.5 級標準。Sandblasting is the best way to clean CS material. Except for purging with dry oil-free air and cleaning particles with clean cloth, no need to use other cleaning methods. Therefore the first step for CS pipes is inside & outside sandblasting with grade Sa2.5.噴沙后應用無油壓縮

29、空氣將管道中的沙粒、鐵銹等雜質吹掃干凈。Blowing out the foreign matters such as dust and rust with compressed oil-free air after sandblasting.清潔后的管道應立即進行保護，管口應密封以防止灰塵和潮濕氣體進入。Cleaning finished pipes shall be protected immediately: close pipe ends to prevent dust and moisture entering.管道外部應立即刷上底漆，防止生銹。Primer shall be app

30、lied outside the pipes immediately to prevent rust.檢查方法 Inspection Method噴砂后的管道必須進行白光檢查。The sandblasted pipes must be inspected with bright light.噴砂施工要求 Sandblasting Requirements噴砂噴射只能由操作員進行操作。Sandblasting shall only be manual operated by specified operator.注意按照 EPI 著裝（不能滲透的連衫褲工作服，帶袖子的手套，防滑底的靴子，帶遮光眼

31、罩的安全帽，降噪裝置，甲子或皮革圍裙） 。Dress as per EPI (impervious one-piece suit, gloves with sleeves, non-skid boots, helmet with eyeshade, noise reduction device and armor /leather apron).不銹鋼管道，管件和 1.5m 以下直徑管道的清洗工藝：（槽浸法）Oxygen Cleaning (SO) Process for SS Pipe (Diameter Less than 1.5m) and Fitting: (Tank Soaking)

32、槽浸法中清洗液的配制；我們選擇0的 NaOH 溶液作為脫脂劑，選擇 HNO3 作為鈍化液對管道進行鈍化。Cleaning solution preparation for tank soaking: 15-20% NaOH solution will be degreasing agent; 25-30% HNO3 solution will be passivation agent.脫脂劑的配制方法：首先清洗工人將潔凈水放入到脫脂槽中，量出水的高度約為 0.5m，然后將適量的固體 NaOH 溶于脫脂槽中，使溶液的濃度約為 20%左右。Method of degreasing agent pr

33、eparation: The cleaning worker input clean water into degreasing tank with height of about 0.5m, dissolve adequate solid NaOH in the tank with concentration about 20%.7.6 不銹鋼管道管件的清洗；SS Pipe, Fitting and Vessel Cleaning對表面污漬，油斑較嚴重的部位，應先用尼龍毛刷和異丙醇反復刷洗For the place where has much dirt, oil and so on, it

34、 shall be brushed with nylon fiber brush and isopropyl alcohol again and again.在常溫下，將要清洗的材料浸入到脫脂槽中并記錄開始時間，每隔 20 分鐘翻轉一次，共計張家港保稅區(qū)利柏特鋼制品有限公司Zhangjiagang FTZ Libaite Steel Products Co., Ltd. Page 7 of 11SO2/CO2 CAPTURE DEMO PLANT FABRICATION AND ASSEMBLY OF MODULES1-2 小時左右，目測管道管件的潔凈度經目測合格后把脫脂后的材料放入到沖洗池中

35、，用高壓水槍進行沖洗，直到附著在上面的溶液和雜質全部沖洗干凈。In the normal temperature, immerge the materials into degreasing tank and record the time started; turn them each 20 minutes in 1-2 hours; visual test the cleanliness ,if it is accepted, put the material degreased into flushing tank and flush with high-pressure squirt

36、gun till clean off all the solution and contaminant adhered.在常溫下，再把沖洗過后材料放到酸洗（鈍化）槽中浸泡 30min 左右進行鈍化并記錄時間，酸洗槽中撈出來后再用清潔的自來水沖洗干凈（最終清洗水的酸堿度應在 68 之間，臨界應用情況下，其酸堿度應在 6.57.5 之間。為減少腐蝕，酸洗成功或鈍化過程與沖洗過程之間不允許對表面進行干燥。最終水沖洗之后，應進行完全干燥） In the normal temperature, soak the materials in pickling/passivating tank about 3

37、0 minutes after flushing finished and record the time; flush with clean tap water after took out of the pickling tank (PH value of final rinse water shall be 6-8, while in critical conditions, the PH value of which shall be 6.5-7.5. in order to reduce corrosion, its not allowed to dry surface after

38、pickled or between passivation and rinsing; which shall be dried completely after final rinsing finished).鈍化后的材料用干燥無油的壓縮空氣吹干并用潔凈管帽封蓋好 Blow with dry oil-free compressed air after passivation and cover with clean caps.用槽浸法初洗完的管件，應目檢和使用黑光燈，檢驗合格后方可進行下一道工序。The next step shall be executed only if test qua

39、lified with methods of Wood lamp or visual inspection after soaking in the tank.清洗后的材料經檢查合格后，要密封保護，管子的兩端用無油的 0.15 毫米的聚乙烯塑料薄膜或塑料管冒密封起來,管件要 0.15mm 聚乙烯塑料薄膜或其它把管口包裝， ，法蘭用干凈的塑料布加 5 合板密封（或者使用成品塑料法蘭蓋） ，螺紋連接件用塑料或金屬密封，金屬冒，管端用潔凈無油的管帽或塑料管封堵。The pipes cleaned and test qualified shall be sealed. Both ends of pip

40、es shall be covered with oil-free polyethylene film of 0.15mm thick or plastic caps; fittings shall be packed with polyethylene film of 0.15mm thick or other proper materials; flanges shall be sealed with clean plastic plate and plywood (or finished-product flange cap); threaded components shall be

41、enclosed with plastic or metallic materials; ends of pipes shall be plugged with clean oil-free caps or plastic materials.以上過程完成后，操作者都必須按清洗記錄的表格形式認真填寫記錄見附錄（清洗記錄表）Operators must fill the records according to related format after above process finished. See appendix I (Cleaning Record).8表面清潔度檢驗、驗收方法：表

42、面清潔度檢驗、驗收方法：Inspection & Acceptance Methods for Surface Cleanliness8.1 直觀檢查 Direct Visual Inspection在明亮的燈光下，用肉眼檢查應清洗表面，表面應無可見的油脂斑、油漆、涂料以及其它顆粒物質，如金屬屑、焊渣、飛濺物、氧化皮、砂子等。如有以上任何污染物，該零部件應重新清洗。Irradiate the piping inside surface with white light, visual inspect the cleaned surface shall be no 張家港保稅區(qū)利柏特鋼制

43、品有限公司Zhangjiagang FTZ Libaite Steel Products Co., Ltd. Page 8 of 11SO2/CO2 CAPTURE DEMO PLANT FABRICATION AND ASSEMBLY OF MODULESvisible grease, paint, coating and other particle such as metallic chip, welding slag, splash, scale and sand. If any contaminant above appeared, the component shall be cl

44、ean again.8.2 黑光燈檢測 Ultraviolet Radiation/Dark Light Test應使用波長 320380um 的黑光燈，功率為 125w，光度大于 100um/cm2 型號為125。Wood lamp (wavelength: 320380um, power: 125w, luminosity: more than 100um/cm2, model: YX125) shall be applied.將需檢測的零部件放置到檢測專用的集裝箱內，集裝箱用黑布遮掩，打開黑光燈，對待檢測表面逐塊檢測。如可見油污熒光,做出標記,對該零部件重新清洗。對于較狹窄，無法用黑燈光

45、檢測部件，取清潔干燥的脫脂白布擦拭被測表面，擦拭面積不小于 0.12，然后用黑光燈檢測該白布，如有熒光反應，應對該部件進行重新清洗，直到驗收合格。Put the components ready or inspection in a special container which was covered with black cloth; turn on Wood lamp and inspect the component one by one. If any oil pollution fluorescence appeared, mark and re-clean it. For nar

46、row parts cant be inspected by dark light lamp, wipe the surface (not less than 0.1 m2) with clean degreased white cloth and inspect it with dark light lamp, any fluorescence appeared means it shall be cleaned again, until its cleaned thoroughly.清洗檢測合格的部件，應包裝好，封閉好，防止二次污染。Cleaning record shall be fil

47、led with relevant date, cleaner and inspector.9酸堿濃度的定期檢測和維持：酸堿濃度的定期檢測和維持：Periodical Inspection & Maintenance of Acid-base Concentration經過一定時間的清洗后，酸堿的濃度會有一定的下降，這時，我們需要定期進行酸堿濃度的檢測。根據施工強度，原則上每星期檢查一次，由質檢部門派人進行測定。對脫脂槽、鈍化槽要定期清洗以保證清洗液合格，清洗有效。The acid-base concentration will drop a little after cleaning

48、, so acid-base concentration shall be inspected periodically (inspect once a week in principle depending on the actual construction strength). The value shall be checked weekly and inspected by QC department. Clean degreasing tank and passivation tank periodically to ensure qualified solution and cl

49、eaning effect.10管道焊口清洗管道焊口清洗 Cleaning of Pipe Welds 管道焊縫兩面都應在開始焊接前進行清洗。清洗時，用無絨白布粘異丙醇清洗劑進行清洗。接頭經過焊接冷卻后，用打磨的方法去除所有可接近的焊接飛濺、焊接焊劑、污垢等。根據具體應用，焊縫的非工藝面上允許有一些污垢或熱調和劑，但可能的話應從工藝面清除。如認為有必要采用化學方法清洗焊縫，建議使用不銹鋼快速酸洗鈍化膏進行清洗（具體見照片）The both faces of the weld should be cleaned immediately before starting to weld. Clean

50、ing may be accomplished with scrubbing with a clean ,lint-free cloth moistened with isopropyl alcohol detergent. When the joint has cooled after welding, remove all accessible weld spatter, welding flux, scale, arc strikes, etc., by grinding. According to the application, some scale or heat temper m

51、ay be permissible on the nonprocess side of a weld, but should be removed from the process side if possible. If 張家港保稅區(qū)利柏特鋼制品有限公司Zhangjiagang FTZ Libaite Steel Products Co., Ltd. Page 9 of 11SO2/CO2 CAPTURE DEMO PLANT FABRICATION AND ASSEMBLY OF MODULESchemical cleaning of the weld is deemed necessar

52、y, it suggests using fast pickling/passivating cream for stainless steel as showed in below picture.11廢液溶解：廢液溶解：Waste Solution Treatment因廢液隨便排放污染環(huán)境，我公司請專業(yè)處理廢液的公司進行回收處理。The waste solution will be recycled and treated by professional company as they could pollute the environment if drainage at random.

53、12安全保護：安全保護：Security硝酸是一種強氧化劑，與有機物，松節(jié)油，水，有機織物接觸會自燃，燃燒是會產生有毒氣體，因此儲藏時必須把容器封嚴，防止滴漏，且應設專用庫房，禁止與有機物，酸類等氧化物接觸。嚴禁把水倒入硝酸液體內。Nitric acid is a kind of strong oxidizer which will cause spontaneous combustion (poisonous gas will be produced from it) after contact with organic matter, turpentine, water and organ

54、ic fabric; during storage, the vessel must be sealed to prevent leakage in special warehouse and avoid contact with organic matter and acid oxide. Its forbidden to pour water into nitric acid.當酸液和堿液濺出和溢出后，應使用木屑和沙子將其吸干，然后用大量清水進行沖洗。Sawdust and sand shall be applied to absorb the acid and basic liquid

55、spilled out; after that flush with clean water.當酸液和堿液滴在皮膚上后，立即用清水進行沖洗，不得搓揉。When acid or basic liquid 張家港保稅區(qū)利柏特鋼制品有限公司Zhangjiagang FTZ Libaite Steel Products Co., Ltd. Page 10 of 11SO2/CO2 CAPTURE DEMO PLANT FABRICATION AND ASSEMBLY OF MODULESdrip on skin, do not rub with hands but flush with clean water immediately.清洗施工人員均需進行上崗前培訓后方可上崗作業(yè)，進入施工現場前接受安全教育。All workers could opera