管道清洗方案.docx

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1、管 道 清 洗 方 案PIPING CLEANING PROCEDUREDOCUMENT NO: LBT-PROCEDURE-004Project Name: TAI CANG P&G Project No:第一次发放01stIssue版本号Rev签发或版本说明Issue or Revision Description编制人Origin by日期Date审核人Review by日期Date批准人Approve by日期Date业主Client日期Date名目Table of Contents1、工作范围 Scope22、编制依据 Reference33、外表清洁度 Surface Cleanl

2、iness34、人员培训 Personnel Training45、污染物鉴定 Contaminant Identification.46、清洗范围 Cleaning Scope47、清洗程序SOOxygen Cleaning Procedure (SO)58、外表清洁度检验、验收方法Inspection & Acceptance Methods for Surface Cleanliness79、酸碱浓度的定期检测和维持Periodical Inspection & Maintenance of Acid-base Concentration710、 管道焊口清洗 Cleaning of P

3、ipe Welds811、 废液溶解 Waste Solution Treatment912、 安全保护 Security913、 溶液酸碱浓度检测方法 PH Concentration Inspection Methods for Cleaning Solution91 工作范围：Scope 3 of 9为标准Tai Cang P&G模块管道清洁施工流程，明确工艺要求，编制此方案。This procedureis proposed to standardize piping cleaning process and define relevant process requirements f

4、orTai Cang P&G System Project.2 编制依据：ReferenceASTM A380-06 不锈钢部件设备系统的清洁&除垢&钝化 Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems3 外表清洁度：Surface Cleanliness3.1 全部应清洁的外表在光明的灯光及紫外线照耀下，不得有可见的污染物。Any visible contaminant is not allowed to appear on

5、cleared surface under bright light or ultraviolet radiation.3.2 全部清洁外表，油脂含量应小于100mg/m2,用波长320380um 功率为w 的紫光照耀下时, 外表不得有油脂荧光。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

6、.3.3 用于清洗的设备和工具要保持干净，并与其它工具分开放置，全部工具在每次使用前彻底清洗干净， 这也包括部件最终清洁使用的试验设备。清洗用的特别工具、材料、测试仪器在使用前必需彻底清 洁。所用的工具包括：测试仪器、吊装工具、吹扫设备、轻松手开工具。The equipments and tools for oxygen cleaning must keep clean and separated from others; all tools shall be clearedthoroughly prior to application, including test apparatus fo

7、r components final cleaning. Specialtools, materials, and test instruments for cleaning must be cleared thoroughly. The tools to be applied include: test instruments, lifting tools, blowing equipments and portable hand tools.3.4 在使用前用无毛绒干净布沾上异丙醇擦拭，确保它们无油、灰尘、碳氢化合物、油漆等。用黑光灯 检验无荧光反响。工作平台应用无油的清洁的聚乙烯薄膜铺垫

8、，掩盖好。用于清洗的清洗剂应保持 干净、有效，不行反复循环使用。清洁好的工具用一个干净的工具箱装好，不允许和其它工具混装。Wipe with clean, lint-free cloth wet by isopropyl alcohol 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 b

9、e put and covered on work platform. Detergent for cleaning shall be clean and efficient, recycled using is not allowed. Cleaned tools shall be packed in a clean tool-box to avoid mixing with others.3.5 我们使用的设备包括：Equipments applied including:喷砂车间一个 One sandblasting workshop酸洗槽一个 One pickling tank 730

10、0MM 长length 950MM 宽width 900MM 高height脱脂槽一个 One degreasing tank 7300MM 长length 2300MM 宽width 900MM 高height 高压干净水枪 流量 200 升/小时，压力为8 公斤/厘米3High-pressure squirt gun with flow rate of 200L/hour and pressure of 8kg/cm3行车或汽车吊5T一台 One traveling crane or truck crane (5t)空气压缩机一台 流量 10m3/min，压力为8 公斤/厘米One air

11、 compressor with flow rate of 10m3/second and pressure of 8kg/cm3清洗场地：清洗场地分为清洗区和待清洗区2 个区，该区域要求明确标识隔离Cleaning site: it was divided to 2 isolated areas of cleaning and ready-for-cleaning with clear marks.4 人员培训：Personnel Training全部从事清洗的人员都必需经过严格的培训，让他们了解清洗程序，清洁设备，用于清洗的清洁 剂的使用方法以及清洗的安全常识。公司必需供给指定的安全手册给

12、这些职员。建立各种必要的 安全设施设备及个人防护用品，全部施工人员应了解各种工作存在的潜在危急，在施工过程中， 施工人员正确配带PPE。All personnel implement cleaning must be trained strictly to know thecleaning process, equipment, cleaning agent application methods and safety common sense of cleaning. The company shall provide specified safety manual, apparatus a

13、nd PPE; during construction, all personnel must understand any potential risks, properly wear PPE and take with safety manual.从事清洁工作的工人应承受全面培训，要意识到不充分不适当的清洁方法会产生严峻的后果。All workers take charge of oxygen cleaning shall be trained overall to understand insufficient and unsuitable cleaning method will ca

14、use serious aftermath.工人应穿上特定的工作服，工作时手必需戴干净防酸手套。为防止清洁液或清洗剂溅入眼睛，工作时应戴上有侧面罩的安全眼睛镜和面罩。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 cleaning solution or agent splashed into eyes.尽可能避

15、开身体暴露部位接触清洗液，清洗时应戴上橡皮手套。全部氧化物溶剂吸入确定量时对 人体有害，因此，当用氯化物进展清洗时应在室外或通风良好的条件下进展，或使用适当的呼吸 器如氧气面罩。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 with chlorides shall be executed outside or well-ven

16、tilated, or wear suitable breather (such as oxygen mask).全部的装置，工具，化学物质要分开安全存放以保证安全，有毒，易燃的物质要有明显的危急标识。All device, tools and chemicals shall be stored separately to ensure their safety; toxic and flammable materials shall be marked clearly.5 污染物鉴定：Contaminant Identification原材料外表携带的污染物，如油脂，碳氢化合物，防锈剂等应用

17、黑光灯检测，是否有荧光反响。The contaminants on materials such as grease, hydrocarbon or anti-rust agent shall be inspected with Wood lamp if they appear fluorescence.加工过程中触及的污染物。如用于机械切割的冷却润滑油等，如荧光反响，应在此类润滑油添 加显荧光剂。Contaminant produced during machining. (such as add fluorescent developer into cooling lubricant fo

18、r mechanical cutting)6 清洗范围Cleaning Scope管道材料脱脂、酸洗钝化。Piping Material Degreasing & Passivating由于是装置，管道及系统不需要进展除垢处理 Piping and system are not required to receive descaling as they are all new.7 清洗程序SO：Oxygen Cleaning Procedure (SO)7.1 模块管道制造程序大体可分为：Fabricating procedure for module pipes shall be divid

19、ed into:7.2 材料的承受和检验材料合格证或质保书Material acceptance & inspection (material certificate or QA document)班组领料Material issuance全部的管件进展清洗Cleaning下料Cutting管段组对管段不超过两个弯头Spools fit-up (each spool shall not exceed 2 elbows)管段彻底清洗管段按要求先做NDECleaning spools thoroughly (NDE first as per related requirements)标识移植Mar

20、king transplant管道现场安装留意保持管段内部清洁度 Installation on site (pay special attention to keep the inside cleanliness of pipes)焊口检查PT/RTWelds testing管道试压Pressure Testing验收Acceptance.7.3 清洗的过程包括原材料的清洗，组装过程中的清洗和保护。对于碳钢材料的清洗我们承受喷砂除 锈的方法进展脱脂。对于不锈钢材料的清洗我们承受槽浸法，安装过程中，材料受到2 次污染我们承受溶剂，异丙醇擦拭。The cleaning including the

21、 cleaning and protection for original materials and assembling 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 为了彻底地清洁管子与管件的主要污染物油，灰尘，微粒，潮湿气体等

22、，我们必需依据标准。 In order to clean the main contaminants (grease, dust, particle moisture) of pipes and fittings thoroughly, we must fully follow the specifications associated.对碳钢管道外部承受喷砂处理同时内壁保持清洁。Outer of CS pipes shall be subject to sandblasting (the inner wall should be kept clean meanwhile).不锈钢承受化学溶液

23、进展清洗，配制所需要的化学溶剂，管道和管件承受槽浸法，主要针对于1.5m 直径以下的管道和管件的清洗。, 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 碳钢管的清洗CS Pipes Cleaning喷砂处理应在适宜的温度条件和湿度下进展温度高于10 度，相对湿度低于70%San

24、dblasting shall be executed in suitable temperature and humidity (temperature more than 10 and relative humidity less than 70%).对灰色金属承受喷砂处理是对清扫碳钢件的最正确方法。除了用无油、枯燥的压缩空气吹扫、拖帚 清扫彻底去除颗粒外,不必再用另外的清扫方法。因此对于碳钢管道均承受外喷沙的方式进展处理， 管道喷砂应到达Sa2.5 级标准。Sandblasting is the best way to clean CS material. Except for purg

25、ing 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.喷沙后应用无油压缩空气将管道中的沙粒、铁锈等杂质吹扫干净。Blowing out the foreign matters such as dust and rust with compressed oil-fre

26、e air after sandblasting.清洁后的管道应马上进展保护，管口应密封以防止灰尘和潮湿气体进入。Cleaning finished pipes shall be protected immediately: close pipe ends to prevent dust and moisture entering.管道外部应马上刷上底漆，防止生锈。Primer shall be applied outside the pipes immediately to prevent rust.检查方法 Inspection Method喷砂后的管道必需进展白光检查。The sandb

27、lasted pipes must be inspected with bright light.喷砂施工要求 Sandblasting Requirements喷砂喷射只能由操作员进展操作。Sandblasting shall only be manual operated by specifiedoperator.留意依据 EPI 着装不能渗透的连衫裤工作服，带袖子的手套，防滑底的靴子，带遮光眼罩的安全帽，降噪装置，甲子或皮革围裙。Dress as per EPI (impervious one-piece suit, gloves with sleeves, non-skid boots

28、, helmet with eyeshade, noise reduction device and armor /leather apron).不锈钢管道，管件和1.5m 以下直径管道的清洗工艺：槽浸法Oxygen Cleaning (SO) Process for SS Pipe (Diameter Less than 1.5m) and Fitting: (Tank Soaking)槽浸法中清洗液的配制；我们选择0的NaOH 溶液作为脱脂剂，选择 HNO3 作为钝化液对管道进展钝化。Cleaning solution preparation for tank soaking: 15-20

29、% NaOH solution will be degreasing agent; 25-30% HNO3 solution will be passivation agent.脱脂剂的配制方法：首先清洗工人将干净水放入到脱脂槽中，量出水的高度约为0.5m，然后将适量的固体NaOH 溶于脱脂槽中，使溶液的浓度约为20%左右。Method of degreasing agent preparation: The cleaning worker input clean water into degreasing tank with height of about 0.5m, dissolve ad

30、equate solid NaOH in the tank with concentration about 20%.7.6 不锈钢管道管件的清洗；SS Pipe, Fitting and Vessel Cleaning对外表污渍，油斑较严峻的部位，应先用尼龙毛刷和异丙醇反复刷洗For the place where has much dirt, oil and so on, it shall be brushed with nylon fiber brush and isopropyl alcohol again and again.在常温下，将要清洗的材料浸入到脱脂槽中并记录开头时间，每隔

31、20 分钟翻转一次，共计1-2 小时左右，目测管道管件的干净度经目测合格后把脱脂后的材料放入到冲洗池中，用高压水枪进 行冲洗，直到附着在上面的溶液和杂质全部冲洗干净。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 int

32、o flushing tank and flush with high-pressure squirt gun till clean off all the solution and contaminant adhered.在常温下，再把冲洗过后材料放到酸洗钝化槽中浸泡 30min 左右进展钝化并记录时间， 酸洗槽中捞出来后再用清洁的自来水冲洗干净最终清洗水的酸碱度应在68 之间，临界应用状况下，其酸碱度应在6.57.5 之间。为削减腐蚀，酸洗成功或钝化过程与冲洗过程之间不允许对外表进展枯燥。最终水冲洗之后，应进展完全枯燥In the normal temperature, soak the

33、materials in pickling/passivating tank about 30 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 co

34、rrosion, its not allowed to dry surface after pickled or between passivation and rinsing; which shall bedried completely after final rinsing finished).钝化后的材料用枯燥无油的压缩空气吹干并用干净管帽封盖好 Blow with dry oil-free compressed air after passivation and cover with clean caps.用槽浸法初洗完的管件，应目检和使用黑光灯，检验合格前方可进展下一道工序。The

35、 next step shall be executed only if test qualified with methods of Wood lamp or visual inspection after soaking in the tank.清洗后的材料经检查合格后，要密封保护，管子的两端用无油的0.15 毫米的聚乙烯塑料薄膜或塑料管冒密封起来,管件要0.15mm 聚乙烯塑料薄膜或其它把管口包装，法兰用干净的塑料布加5 合板密封或者使用成品塑料法兰盖，螺纹连接件用塑料或金属密封，金属冒，管端用干净无 油的管帽或塑料管封堵。The pipes cleaned and test quali

36、fied shall be sealed. Both ends of pipes 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 sealedwith clean plastic plate and plywood (or finished-product flang

37、e cap); threaded components shall be enclosed with plastic or metallic materials; ends of pipes shall be plugged with clean oil-free caps or plastic materials.以上过程完成后，操作者都必需按清洗记录的表格形式认真填写记录见附录清洗记录表 Operators must fill the records according to related format after above process finished. See appendix

38、 I (Cleaning Record).8 外表清洁度检验、验收方法：Inspection & Acceptance Methods for Surface Cleanliness8.1 直观检查Direct Visual Inspection在光明的灯光下，用肉眼检查应清洗外表，外表应无可见的油脂斑、油漆、涂料以及其它颗粒物 质，如金属屑、焊渣、飞溅物、氧化皮、砂子等。如有以上任何污染物，该零部件应重清洗。Irradiate the piping inside surface with white light, visual inspect the cleaned surface shal

39、l be no visible 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 clean again.8.2 黑光灯检测Ultraviolet Radiation/Dark Light Test应使用波长 320380um 的黑光灯，功率为125w，光度大于100um/cm2 型号为125。Wood lamp (wavele

40、ngth: 320380um, power: 125w, luminosity: more than 100um/cm2, model: YX125) shall be applied.将需检测的零部件放置到检测专用的集装箱内，集装箱用黑布遮掩，翻开黑光灯，对待检测外表 逐块检测。如可见油污荧光,做出标记,对该零部件重清洗。对于较狭窄，无法用黑灯光检测部件， 取清洁枯燥的脱脂白布擦拭被测外表，擦拭面积不小于0.12，然后用黑光灯检测该白布，如有 荧光反响，应对该部件进展重清洗，直到验收合格。Put the components ready or inspection ina special c

41、ontainer 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 narrow parts cant be inspected by dark light lamp, wipe the surface (not less than 0.1 m2) with clean degreased white cloth and i

42、nspect it with dark light lamp, any fluorescence appeared means it shall be cleaned again, until its cleaned thoroughly.清洗检测合格的部件，应包装好，封闭好，防止二次污染。Cleaning record shall be filled with relevant date, cleaner and inspector.9 酸碱浓度的定期检测和维持：Periodical Inspection & Maintenance of Acid-base Concentration 经过

43、确定时间的清洗后，酸碱的浓度会有确定的下降，这时，我们需要定期进展酸碱浓度的检测。依据施工强度，原则上每星期检查一次，由质检部门派人进展测定。对脱脂槽、钝化槽要定期清洗以保 证清洗液合格，清洗有效。The acid-base concentration will drop a little after cleaning, so acid-base concentration shall be inspected periodically (inspect once a week in principle depending on the actual construction strength

44、). The value shall be checked weekly and inspected by QC department. Clean degreasing tank and passivation tank periodically to ensure qualified solution and cleaning effect.10 管道焊口清洗 Cleaning of Pipe Welds管道焊缝两面都应在开头焊接前进展清洗。清洗时，用无绒白布粘异丙醇清洗剂进展清洗。接头经 过焊接冷却后，用打磨的方法去除全部可接近的焊接飞溅、焊接焊剂、污垢等。依据具体应用，焊 缝的非工艺面

45、上允许有一些污垢或热调和剂，但可能的话应从工艺面去除。如认为有必要承受化学 方法清洗焊缝，建议使用不锈钢快速酸洗钝化膏进展清洗具体见照片The both faces of the weld should be cleaned immediately before starting to weld. Cleaning may be accomplished with scrubbing with a clean ,lint-free cloth moistened with isopropyl alcohol detergent. When the joint has cooled after

46、welding, remove all accessible weld spatter, welding flux, scale, arc strikes, etc.,by grinding. According to the application, some scale or heat temper may be permissible on the nonprocess side of a weld, but should be removed from the process side if possible. If chemical cleaning of the weld is d

47、eemed necessary, it suggests using fast pickling/passivating cream for stainless steel as showed in below picture.11 废液溶解：Waste Solution Treatment因废液任凭排放污染环境，我公司请专业处理废液的公司进展回收处理。The waste solution will be recycled and treated by professional company as they could pollute the environment if drainage at random.12 安全保护：Security硝酸是一种强氧化剂，与有机物，松节油，水，有机织物接触会自燃，燃烧是会产生有毒气体， 因此贮存时必需把容器封严，防止滴漏，且应设专用库房，制止与有机物，酸类等氧化物接触。严禁把水倒入硝酸液体内。Nitric acid is a kind of st