管道清洗方案(Rev.B)

1、 张家港保税区利柏特钢制品有限公司张家港保税区利柏特钢制品有限公司Zhangjiagang FTZ Libaite Steel Products Co., Ltd.中国中国 江苏省江苏省 张家港市张家港市 张家港保税区张家港保税区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第二次发布2nd Issue王忠建A第一次发布First Issue王忠建版本号Rev签发或版本说明Issue or Revision Desc

2、ription编制人Prepared by日期Date审核人Reviewed by日期Date批准人Approved by日期DateCTI日期Date张家港保税区利柏特钢制品有限公司Zhangjiagang FTZ Libaite Steel Products Co., Ltd. Page 2 of 11SO2/CO2 CAPTURE DEMO PLANT FABRICATION AND ASSEMBLY OF MODULES目 录Table of Contents1、工作范围：Scope.32、编制依据：Reference .33、表面清洁度：Surface Cleanliness .34

3、、人员培训：Personnel Training.45、污染物鉴定：Contaminant Identification.46、清洗范围 Cleaning Scope .57、清洗程序（SO）：Oxygen Cleaning Procedure (SO).58、表面清洁度检验、验收方法：Inspection & Acceptance Methods for Surface Cleanliness.79、酸碱浓度的定期检测和维持：Periodical Inspection & Maintenance of Acid-base Concentration.810、管道焊口清洗 Cleaning o

4、f Pipe Welds.811、废液溶解：Waste Solution Treatment .912、安全保护：Security.913、溶液酸碱浓度检测方法 PH Concentration Inspection Methods for Cleaning Solution -10张家港保税区利柏特钢制品有限公司Zhangjiagang FTZ Libaite Steel Products Co., Ltd. Page 3 of 11SO2/CO2 CAPTURE DEMO PLANT FABRICATION AND ASSEMBLY OF MODULES1工作范围：工作范围：Scope为规

5、范 Cansolv 公司 SO2/CO2 收集模块管道清洁施工流程，明确工艺要求，编制此方案。This procedure is proposed to standardize piping cleaning process and define relevant process requirements for Cansolv SO2/CO2 capture System Project.2编制依据：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 Pass

6、ivation of Stainless Steel Parts, Equipment, and Systems3表面清洁度：表面清洁度：Surface Cleanliness3.1所有应清洁的表面在明亮的灯光及紫外线照射下，不得有可见的污染物。Any visible contaminant is not allowed to appear on cleared surface under bright light or ultraviolet radiation.3.2所有清洁表面，油脂含量应小于 100mg/m2,用波长 320380um 功率为w 的紫光照射下时,表面不得有油脂荧光。Fo

7、r 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用于清洗的设备和工具要保持干净，并与其它工具分开放置，所有工具在每次使用前彻底清洗干净，这也包括部件最后清洁使用的实验设备。清洗用的特殊工具、材料、测试仪器在使用前必须彻底清洁。所用的工具包括：测试仪器、吊装工具、吹扫设备、轻便手动工具。Th

8、e 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 thoroughly. The tools

9、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应。工作平台应用无油的清洁的聚乙烯薄膜铺垫，覆盖好。用于清洗的清洗剂应保持洁净、有效，不可反复循环使用。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 u

10、sing 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 allowed. Cleaned

11、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 7300MM 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高压洁净水枪 流量 200 升/小

12、时，压力为 8 公斤/厘米 3 High-pressure squirt gun with flow rate of 200L/hour and pressure of 8kg/cm3张家港保税区利柏特钢制品有限公司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/

13、min，压力为 8 公斤/厘米One air 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：人员培训：Personnel Training 所有从事清洗的人员都必须经过严格的培训，让他们了解清洗程序，清洁设备，用于清洗的清洁剂的使

14、用方法以及清洗的安全常识。公司必须提供指定的安全手册给这些职员。建立各种必要的安全设施设备及个人防护用品，所有施工人员应了解各种工作存在的潜在危险，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 the cleaning process, equipment, cleaning agent application methods and safety common sense of cleaning. The company shall provide specified

15、 safety manual, apparatus and PPE; during construction, all personnel must understand any potential risks, properly wear PPE and take with safety manual. 从事氧清洁工作的工人应接受全面培训，要意识到不充分不适当的清洁方法会产生严重的后果。All workers take charge of oxygen cleaning shall be trained overall to understand insufficient and unsui

16、table cleaning method will cause serious aftermath. 工人应穿上特定的工作服，工作时手必须戴干净防酸手套。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

17、 agent splashed into eyes. 尽可能避免身体暴露部位接触清洗液，清洗时应戴上橡皮手套。所有氧化物溶剂吸入一定量时对人体有害，因此，当用氯化物进行清洗时应在室外或通风良好的条件下进行，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 shal

18、l be executed outside or well-ventilated, or wear suitable breather (such as oxygen mask). 所有的装置，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险标识。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：污染物鉴定：Contaminant Id

19、entification原材料表面携带的污染物，如油脂，碳氢化合物，防锈剂等应用黑光灯检测，是否有荧光反应。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，如荧光反应，应在此类润滑油中添加显荧光剂。 ）Contaminant produced during machining. (such as add flu

20、orescent 张家港保税区利柏特钢制品有限公司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清洗范围清洗范围 Cleaning Scope管道材料脱脂、钝化。Piping Material Degreasing & Passivating由于是新装置，管道及系统不需要进行除垢处理

21、 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 模块管道制造程序大体可分为：Fabricating procedure for module pipes shall be divided into: 7.2 材料的接受和检验（材料合格证或质保书）Material acceptance & inspection (material certificate or QA document) 班组

22、领料 Material issuance 所有的管件进行清洗 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 NDE）Cleaning spools thoroughly (NDE first as per related requirements) 标识移植 Marking transplant 管道现场安装（注意保持管段内部清洁度）Installation on site (pay special attention to keep

23、the inside cleanliness of pipes) 焊口检查（PT/RT）Welds testing 管道试压 Pressure Testing 验收 Acceptance7.3 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采用喷砂除锈、脱脂的方法。对于不锈钢材料的清洗我们采用槽浸法，安装过程中，材料受到 2 次污染我们采用溶剂，异丙醇擦拭。The cleaning including the cleaning and protection for original materials and assembling process. Sandblas

24、ting 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） ，我们必须根据规范。In order to clean the main contaminants (grease, dust, particle moi

25、sture) of pipes and fittings thoroughly, we must fully follow the specifications associated.对碳钢管道外部采用喷砂处理（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).不锈钢采用化学溶液进行清洗，配制所需要的化学溶剂，管道和管件采用槽浸法，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

26、 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行（温度高于 10 度，相对湿度低于 70%）Sandblasting shall be executed in suitable temperature and humidity (tem

27、perature more than 10 and relative humidity less than 70%).对灰色金属采用喷砂处理是对清扫碳钢件的最佳方法。除了用无油、干燥的压缩空气吹扫、拖帚清扫彻底清除颗粒外,不必再用另外的清扫方法。因此对于碳钢管道均采用外喷沙的方式张家港保税区利柏特钢制品有限公司Zhangjiagang FTZ Libaite Steel Products Co., Ltd. Page 6 of 11SO2/CO2 CAPTURE DEMO PLANT FABRICATION AND ASSEMBLY OF MODULES进行处理，管道喷砂应达到 Sa2.5 级

28、标准。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.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

29、out the foreign matters such as dust and rust with compressed oil-free air after sandblasting.清洁后的管道应立即进行保护，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.管道外部应立即刷上底漆，防止生锈。Primer shall be applied outside the pipes immed

30、iately to prevent rust.检查方法 Inspection Method喷砂后的管道必须进行白光检查。The sandblasted 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行操作。Sandblasting shall only be manual operated by specified operator.注意按照 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 a

31、s per EPI (impervious one-piece suit, gloves with sleeves, non-skid boots, 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

32、脂剂，选择 HNO3 作为钝化液对管道进行钝化。Cleaning solution preparation for tank soaking: 15-20% NaOH solution will be degreasing agent; 25-30% HNO3 solution will be passivation agent.脱脂剂的配制方法：首先清洗工人将洁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 work

33、er 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 不锈钢管道管件的清洗；SS Pipe, Fitting and Vessel Cleaning对表面污渍，油斑较严重的部位，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

34、 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始时间，每隔 20 分钟翻转一次，共计张家港保税区利柏特钢制品有限公司Zhangjiagang FTZ Libaite Steel Products Co., Ltd. Page 7 of 11SO2/CO2 CAPTURE DEMO PLANT FABRICATION AND ASSEMBLY OF MODULES1-2 小时左右，目测管道管件的洁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

35、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 into flushing tank and flush with high-pressure squirt gun till clean off all the s

36、olution 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 左右进行钝化并记录时间，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，临界应用情况下，其酸碱度应在 6.57.5 之间。为减少腐蚀，酸洗成功或钝化过程与冲洗过程之间不允许对表面进行干燥。最终水冲洗之后，应进行完全干燥） In the normal temperature, soak the materials in pickling/passivating tank about 30 minutes after flushing fin

37、ished 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 pickled or between passivati

38、on and rinsing; which shall be dried completely after final rinsing finished).钝化后的材料用干燥无油的压缩空气吹干并用洁净管帽封盖好 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，检验合格后方可进行下一道工序。The next step shall be executed only if test qualified with methods of Wood

39、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，管端用洁净无油的管帽或塑料管封堵。The pipes cleaned and test qualified shall be sealed. Both ends of pipes shall be covered with oil

40、-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 enclosed with plastic or met

41、allic materials; ends of pipes shall be plugged with clean oil-free caps or plastic materials.以上过程完成后，操作者都必须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 I (Cleaning Record).8表面清洁度检验、验收方法：表面清洁度检验、验收方法：Inspection & Acc

42、eptance Methods for Surface Cleanliness8.1 直观检查 Direct Visual Inspection在明亮的灯光下，用肉眼检查应清洗表面，表面应无可见的油脂斑、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，该零部件应重新清洗。Irradiate the piping inside surface with white light, visual inspect the cleaned surface shall be no 张家港保税区利柏特钢制品有限公司Zhangjiagang FTZ Libaite St

43、eel 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 clean again.8.2 黑光灯检测 Ultraviolet

44、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 (wavelength: 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，打开黑光灯，对待检测表面逐块检测。如可见油污荧光,做出标记,对该零部件重新清洗。对于较狭窄，无法用黑灯光检测部件，取清洁干燥的脱脂白布擦拭被测表面，擦拭面积不小于 0.

45、12，然后用黑光灯检测该白布，如有荧光反应，应对该部件进行重新清洗，直到验收合格。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 narrow parts cant be inspected by d

46、ark 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

47、and inspector.9酸碱浓度的定期检测和维持：酸碱浓度的定期检测和维持：Periodical Inspection & Maintenance of Acid-base Concentration经过一定时间的清洗后，酸碱的浓度会有一定的下降，这时，我们需要定期进行酸碱浓度的检测。根据施工强度，原则上每星期检查一次，由质检部门派人进行测定。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 b

48、e 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 cleaning effect.10管道焊口清洗管道焊口清洗 Cleanin

49、g of Pipe Welds 管道焊缝两面都应在开始焊接前进行清洗。清洗时，用无绒白布粘异丙醇清洗剂进行清洗。接头经过焊接冷却后，用打磨的方法去除所有可接近的焊接飞溅、焊接焊剂、污垢等。根据具体应用，焊缝的非工艺面上允许有一些污垢或热调和剂，但可能的话应从工艺面清除。如认为有必要采用化学方法清洗焊缝，建议使用不锈钢快速酸洗钝化膏进行清洗（具体见照片）The both faces of the weld should be cleaned immediately before starting to weld. Cleaning may be accomplished with scrubbi

50、ng 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 may be permissible on the nonprocess

51、side of a weld, but should be removed from the process side if possible. If 张家港保税区利柏特钢制品有限公司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 necessary, it suggests using fast pickling/p

52、assivating cream for stainless steel as showed in below picture.11废液溶解：废液溶解：Waste Solution Treatment因废液随便排放污染环境，我公司请专业处理废液的公司进行回收处理。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：安全保护：Security硝酸是一种强氧化剂，与有机物，松

53、节油，水，有机织物接触会自燃，燃烧是会产生有毒气体，因此储藏时必须把容器封严，防止滴漏，且应设专用库房，禁止与有机物，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 strong oxidizer which will cause spontaneous combustion (poisonous gas will be produced from it) after contact with organic matter, turpentine, water and organic fabric; during storage, the vesse

54、l 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.当酸液和碱液溅出和溢出后，应使用木屑和沙子将其吸干，然后用大量清水进行冲洗。Sawdust and sand shall be applied to absorb the acid and basic liquid spilled out; after that flush with c

55、lean water.当酸液和碱液滴在皮肤上后，立即用清水进行冲洗，不得搓揉。When acid or basic liquid 张家港保税区利柏特钢制品有限公司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.清洗施工人员均需进行上岗前培训后方可上岗作业，进入施工现场前接受安全教育。All workers could operate