Pipeline System Chemical Cleaning

管路化学清洗工艺

CONTENT 目录
CONTENT 目录 ...................................................................................................................................................... 2
1 工程概况 PROJECT OVERVIEW....................................................................................................................... 3
2 编制依据 PREPARING BASIS ............................................................................................................................ 3
3 化学清洗范围 CHEMISTRY CLEANING SCOPE ........................................................................................... 4
4 化学清洗前的准备工作 PREPARATION BEFORE CHEMISTRY CLEANING...........................................4
5 脱脂、除锈（中性）、钝化程序及工艺 PROGRAM AND PROCESS OF DEGREASING, DERUST
(NEUTRAL), PASSIVATION..................................................................................................................................7
6 废液处理和排放 TREATMENT AND EMISSIONS OF WASTE LIQUID.................................................... 16
7 化学清洗质量标准 QUALITY STANDARDS OF CHEMISTRY CLEANING............................................. 16
8 施工管理和安全措施 CONSTRUCTION MANAGEMENT AND SAFETY MEASURES.......................... 17
9 交工验收 COMPLETION OF THE ACCEPTANCE....................................................................................... 19
 1 工程概况 PROJECT OVERVIEW.
本方案针对业主管路系统清洗技术要求而制定。因为管路中的污物，包括：机械加工油脂、二次污染铁锈、
污垢及安装过程产生的杂物等，它们的存在，对安全生产带来隐患，会直接导致产品的污染。
This scheme is formulated for the technical requirements of pipeline system cleaning of the owner. The
pipeline contaminants, including: mechanical processing oil, secondary pollution of rust, dirt and the sundries of
installation process etc. Their existence is dangerous for safe production, and will directly lead to production
contamination.

所以，对于管路系统、设备应进行严格的脱脂、除锈、钝化处理，使管路、设备内表面达到彻底的清
洁要求。
Therefore, the piping system and equipments should be treated strictly with degreasing, derust and
passivation, in order to make inner surface of the pipe and equipments clean thoroughly.

2 编制依据 PREPARING BASIS

 《工业设备化学清洗》中华人民共和国化工行业标准 HG/T2387-2007
< Chemistry Cleaning of Industry Equipments> Chemistry Industry Standard of the People's Republic of
China (HG/T2387-2007)

 《工业管道工程施工及验收规范》中华人民共和国国家标准 GBJ235
<Construction and Acceptance Specification of Industrial Pipeline Engineering > Standard of the People's
Republic of China (GBJ235)

 《污水综合排放标准》（GB8978－99）
<Integrated Wastewater Discharge Standard>（GB8978－99）

 《不锈钢零件，设备和系统的清洗、除锈和钝化标准》 （ASTM A380）

<Standard for cleaning, derusting and passivation of stainless steel parts, equipment and
systems> （ASTM A380）

3 化学清洗范围 CHEMISTRY CLEANING SCOPE

管路系统内表面进行脱脂、除锈及钝化处理。
Degreasing, derusting and passivation treatment shall be carried out on the inner surface of the
pipeline system.

4 化学清洗前的准备工作 PREPARATION BEFORE CHEMISTRY

CLEANING
4.1 工程施工公用设施 Public Facilities of Engineering Construction
●电源：清洗设备摆放场地近清洗系统处；二路三相动力电源至现场设备处动力箱，满足现场动力电源
（380V/220V）。
Power: Cleaning equipment near the cleaning system; Two-way three-phase power supply to the
power box at the field equipment: one power box is for 75KW, the other is for 110KW.

●气源：干燥无油的压缩空气或氮气。

Air: dry compressed clean air or nitrogen.

●厂内叉车和起吊车：清洗泵站系统的移位及吊装。
The forklift and crane: shifting and hoisting of the clean pump station system.

4.2 化学清洗机具 Chemical cleaning equipment（根据实际情况重新编写）

4.3 职责 Responsibilities
（1）施工前，负责清洗范围内的精密仪表的拆除及清洗之后仪表的复位，负责与清洗相关的设备、管道和
阀门的拆卸和复位工作。

Before construction,Party A should be responsible for removing and restoration

working, including precision instruments, related equipment, pipes and valves.

（2）严格遵守双方签定的协议，不得损坏发包方设备、仪表。
Strictly abide by the agreement signed by both parties and shall not damage the
employer's equipment and instruments

（3）负责清洗泵站的操作现场巡视，清洗质量检查。严格按照施工方案施工，保证质量，保证工期。清洗
人员必须熟悉装置流程。
Party B should be responsible for supervising the operation site of the cleaning
pumping station, inspecting the cleaning quality. In accordance with the construction
plan, ensure the quality, guarantee time limit for a project. Cleaning personnel must
be familiar with the process of installation。

4.4 临时措施 Temporary Measure.

（1）查清并确认清洗系统和其他隔离。
Check and confirm cleaning system and other isolation.

（2）绘制清洗系统流程图，系统中阀门应按图纸编号，并挂牌。
Draw cleaning system flow chart, the valves of the system should be numbered according to the
drawing, and make swing tag.

（3）清洗所用材料及药品全部运抵现场。
Materials and medicines related with cleaning all arrived at the scene.

（4）清洗循环泵站及其他机械设备运转合格。
Cleaning circulation pump station and other mechanical equipment operate properly.

（5）清洗临时系统、排污系统（清洗槽至废液回收桶）安装完毕后，水压试验合格。并确保排污系统畅通、
不泄露。
After the installation of the temporary cleaning system and sewerage system (cleaning trough to
waste recycling barrel), water pressure test properly. And ensure sewerage system smooth and not lea

（6）测试仪器准备齐全，在每个清洗系统清洗时清洗槽内挂试片，并进行腐蚀监控和清洗过程监控。
Test equipment is prepared. Cleaning slot should be hung test pieces when each cleaning system
cleaning. Corrosion monitoring and cleaning process monitoring.

（7）清洗系统及清洗水泵等处配备有通讯设备，以便随时联系。
The places, such as cleaning systems and the pumps, are equipped with communication equipment
in order to contact freely.
4.5、化学清洗过程简述 Chemistry Cleaning Process Briefing

配置好临时清洗系统，遵循低进、高出的流体流向原则，在管路最低点设置清洗进液，最高处设置清
洗回液，保证管路内部全充满清洗液体，并在管路底部设排污点，管路高点设置排空。清洗过程中定期排
污、排空。
Configure temporary cleaning system. Follow the principle of lower inlet and higher flow. Set cleaning
feed fluid on low pipeline. Set cleaning return liquid on top pipeline. Ensure internal pipeline filled with
cleaning fluid. Set discharge point at the bottom of the pipe. Set emptying at the top of pipe. Regular
discharging, and emptying in cleaning process.

5 脱脂、除锈（中性）、钝化程序及工艺 PROGRAM AND PROCESS OF

DEGREASING, DERUST (NEUTRAL), PASSIVATION
5.1、碳钢管路系统化学清洗
Chemical cleaning of carbon steel pipeline system

5.1.1、清洗工艺采用循环清洗方式进行：清洗临时泵站—管路系统—清洗临时泵站。
Circulation cleaning method: Cleaning the temporary pumping station---pipeline system--Cleaning
the temporary pumping station.

5.1.2、整个清洗程序按下面步骤进行：
The whole cleaning procedure is carried out according to the following steps:

水冲洗及 除锈 水冲洗
试漏

检查验收 干燥 钝化

Water Descaling Water

flushing and flush
leakage test

check and dry Passiv

acceptance ation

5.1.3、水冲洗及试漏 Water flush and Leak Testing

水冲洗及试漏的目的在除去设备内表面灰尘、脱落的金属氧化物及其他疏松污物，并在模拟清洗状态
下对临时清洗回路进行泄露检查。冲洗时采用高位注水、低点排放，以便排尽系统内污物，控制进出水平
衡。
The purpose of water flush and leak testing is to remove dust of inner surface equipment, deciduous
metal oxide and other loose contaminants, and to check any leaking problem existed for those temporary
cleaning circuit under simulating the cleaning condition. Flush with high water injection and low emissions,
in order to exhaust the sewage in the system and control the balance of water in and out.
5.1.4、除锈（常温）Derust(room temperature)
除锈的目的是利用除锈剂与金属氧化物进行化学反应，生成可溶性物质而除去。为控制除锈率在清洗槽中

3+
放入同材质的试片和监视管段。除锈过程中每小时测定一次溶液中铁离子的含量，当进回液中的铁离子（Fe 、
2+
Fe ）含量浓度趋于平衡时（进回液浓度差小于 100ppm 时），并且进回液浓度趋于平衡（进回液浓度差小于
0.1-0.2%为终点），除锈结束。
The purpose of derust is to utilize derusting agent react with metal oxide to form soluble substances
in order to clean the inner surface of the piping system. To control the derusting rate, put the same
material and monitoring section in the cleaning trough. In the process of derust, testing iron ions
determination in the solution every hour. When the iron ions (Fe3 +, Fe2 +) concentration in the liquid is
closely balanced (the liquid concentration difference is less than 100 PPM), and the liquid concentration is
closely balanced (the fluid concentration difference is less than 0.1 - 0.2%), derust is finished.

(中性)除锈剂：(neutral) Rust remover

质量控制措施及目标 measures and targets of quality control

3+ 2+
总铁含量 Fe Fe 1 次/1 小时
Total content of iron Fe3+ Fe2+ 1time/1 hour

除锈剂浓度 1 次/1 小时 concentration

of Rust remover 1time/1 hour

清洗循环时间 36—56 小时
Cleaning cycle time 36-56 hours

备注：当除锈剂溶液中的铁离子含量大于 1000ppm，必须更换除锈剂，重新配置新的除锈药剂。
Note: when the content of iron ion of Rust remover solution is more than 1000 PPM, Rust remover
must be replaced instead of the new derusting agent.

5.1.5、水冲洗 water flush

除锈结束后，排尽除锈液，用水进行冲洗，除去残留的除锈液及洗下的固体颗粒，冲洗结束。
After derusting, drain the derust liquid and rinse with water to remove the residual pickling liquid and
the solid particles. Rinse is completed.

5.1.6、钝化（常温）Passivation(room temperature)
钝化的目的是通过钝化处理，可在金属表面形成均匀、致密的保护膜，增强耐腐蚀力。
The purpose of passivation is to form the corrosion resistant film on the surface of metal. Thus to
enhance the corrosion resistance.

钝化剂：passivation agent

工艺条件 process conditions

钝化温度 passivation temperature 常温 room temperature

钝化时间 passivation time 1—4 小时 1-4 hours

5.1.7、干燥 dry
排尽系统内残留水份，系统采用无油干燥氮气或压缩空气进行吹扫，吹扫时采用高点进气、低点排气，
在管路末端出气口测试露点为 0 度时（如果业主另有规定，达到业主规定要求），结束吹扫。
Exhaust the residual water in the system, the system adopts oil-free dry nitrogen or compressed air
for purging, and the high inlet and low exhaust are adopted for purging. When the dew-point of the air
outlet at the end of the pipeline is 0 ° (if the owner has other requirements, the dew-point meets the
owner's requirements), the purging shall end.

5.2、不锈钢管路系统化学清洗
Chemical cleaning of stainless steel pipeline system

5.2.1、清洗工艺采用循环清洗方式进行：清洗临时泵站—管路系统—清洗临时泵站。
Circulation cleaning method: Cleaning the temporary pumping station---pipeline system--Cleaning
the temporary pumping station.

5.2.2、整个清洗程序按下面步骤进行：The whole cleaning procedure is carried out according to the

following steps
5.2.3、水冲洗及试漏 Water flush and Leak Testing

水冲洗及试漏的目的在除去设备内表面灰尘、脱落的金属氧化物及其他疏松污物，并在模拟清洗状态
下对临时清洗回路进行泄露检查。冲洗时采用高位注水、低点排放，以便排尽系统内污物，控制进出水平
衡。
The purpose of water flush and leak testing is to remove dust of inner surface equipment, deciduous
metal oxide and other loose contaminants, and to check any leaking problem existed for those temporary
cleaning circuit under simulating the cleaning condition. Flush with high water injection and low emissions,
in order to exhaust the sewage in the system and control the balance of water in and out

5.2.4、脱脂（常温）Degreasing(room temperature)

脱脂处理的目的除去系统内表面在轧制、制作、安装过程中产生的油脂，使酸洗能完全、彻底地和系
统内的金属表面接触，从而使清洗彻底、钝化膜完整；当系统脱脂液浓度平衡（30 分钟内进、回液浓度差
小于 0.1-0.2%），既可结束脱脂。

The purpose of degreasing is to remove oily contaminants adhere to the inner surface of system,
which are produced in the process of rolling, producing and installing. So the pickling can touch metal
surface of the inner system completely and thoroughly, so that the cleaning thoroughly and passivation
membrane integrity. When the degreasing fluid concentration of system is balanced (Within 30 minutes,
in and out liquid concentration difference is less than 0.1-0.2%), degreasing can be finished.

脱脂剂：degreasing agent
工艺条件 process conditions

温度 temperature 常温 room temperature

循环时间 cycle time 2-3 小时

测试项目：脱脂剂浓度 1 次/1 小时
Test item: concentration of degreasing agent 1time/1 hour
5.2.5、脱脂后水冲洗 water flush after degreasing

脱脂后水冲洗的目的除去系统内残存的脱脂剂及脱落的杂质，为酸洗创造条件。
The purpose of water flush after degreasing is to remove residues of degreasing agent and any
detached contaminants in order to prepare pickling.

排出脱脂废液，用大量水冲洗，管路清洗时定期低点排污、高处排空。当排水 pH 值大于 5-6，用视觉

观察冲洗水至透明无微粒，水冲洗步骤结束。
Drain degreasing effluents from pipes and flush with large quantity of water. Regular discharging on
low pipeline, and emptying on top pipeline in cleaning process. Drainage pH is more than 5-6, rinse water
is transparent without particles, water flush is
finished.

5.2.6、酸洗（常温）钝化 Pickling and Passivation (room temperature)

酸洗的目的是利用酸洗剂与金属氧化物进行化学反应，生成可溶性物质而除去。为控制除锈率，在清
洗槽中放入同材质的试片和监视管段。酸洗过程中每小时测定一次溶液中铁离子的含量，当进回液中的铁
离子（Fe3+、Fe2+）含量浓度趋于平衡时（进回液浓度差小于 100ppm 时），并且进回液浓度趋于平衡
（进回液浓度差小于 0.1-0.2%为终点），酸洗结束。

The purpose of pickling is to utilize pickling agent react with metal oxide to form soluble substances
in order to clean the inner surface of the piping system. To control the pickling rate, put the same material
and monitoring section in the cleaning trough. In the process of pickling, testing iron ions determination in
the solution every hour. When the iron ions (Fe3 +, Fe2 +) concentration in the feed and return liquid is

closely balanced (the liquid concentration difference is less than 100 PPM), and the liquid concentration is
closely balanced (the fluid concentration difference is less than 0.1 - 0.2%), end of the pickling.

钝化的目的是通过钝化处理，可在金属表面形成均匀、致密的保护膜，增强耐腐蚀力。
The purpose of passivation is to form the corrosion resistant film on the surface of metal. Thus to
enhance the corrosion resistance.

酸洗剂：Pickling agent

质量控制措施及目标 measures and targets of quality control

酸洗剂浓度 1 次/1 小时
pickling agent concentration 1time/1 hour

清洗循环时间 3—5 小时
Cleaning cycle time 3-5 hours

备注：当酸洗剂溶液中的铁离子含量大于 1000ppm，必须更换酸洗剂，重新配置新的酸洗药剂。
Note: when the content of iron ion of pickling agent solution is more than 1000 PPM, pickling agent
must be replaced with new pickling agent.

5.2.7、水冲洗 water flush

酸洗结束后，排尽酸洗液，用水进行冲洗，除去残留的酸洗液及洗下的固体颗粒，冲洗结束。
After pickling, drain the pickling liquid and rinse with water to remove the residual pickling liquid and
the solid particles. Rinse is completed.
5.2.8、干燥 dry

排尽系统内残留水份，系统采用无油干燥氮气或压缩空气进行吹扫，吹扫时采用高点进气、低点排气，
在管路末端出气口测试露点为 0 度时（如果业主另有规定，达到业主规定要求），结束吹扫。
Exhaust the residual water in the system, the system adopts oil-free dry nitrogen or compressed air
for purging, and the high inlet and low exhaust are adopted for purging. When the dew-point of the air
outlet at the end of the pipeline is 0 ° (if the owner has other requirements, the dew-point meets the
owner's requirements), the purging shall end.

5.3、验收 acceptance
管路在化学清洗工作全部结束后，经过船东验收合格后，用盲板或塑料薄膜封存保护，并悬挂明显标
示，只有在安装的最后时刻才能将包装打开。
After all the chemical cleaning work is finished, the pipeline shall be sealed and protected with blind
plate or plastic film after passing the owner's acceptance, and clearly marked. Only at the last moment of
installation can the package be opened.

6 废液处理和排放 TREATMENT AND EMISSIONS OF WASTE LIQUID

清洗废液处理：按甲方要求把废液排至甲方指定的废液桶内，由甲方联系污水处理厂进行处理。
Waste cleaning liquid treatment: discharge the waste liquid to the waste liquid bucket designated by party
A, and party A shall contact the sewage treatment plant for treatment.

7 化学清洗质量标准 QUALITY STANDARDS OF CHEMISTRY CLEANING

在化学清洗除锈、钝化成膜的过程中，必须控制设备结构材料的腐蚀率和腐蚀量，其指标应不大于国家标
准《工业设备化学清洗质量标准》（HG/T2387-2007）。
During chemistry derusting and passivation film formation, the corrosion rate and amount of the
structural materials of the equipment must be controlled. The corrosion should not exceed those of
specified in <Quality Standard of Chemistry Cleaning of Industry Equipments> (HG/T2387-2007).

7.1、清洗后的金属表面应清洁，无明显金属粗晶析出的过洗现象，不应有镀铜现象；
Metal surface keep clean after cleaning. No obvious metal coarse grain should be appeared. No
copper plating should be formed;

2
7.2、用腐蚀指示片测量的金属平均腐蚀速度应小于 6g/m ·h，腐蚀总量小于
2
72g/m ；除锈（锈）率≥98%；
The average corrosion velocity of the metal measured by the corrosion indicator plate should be
less than 6g/m2•h, and the total corrosion amount should be less than 72g/m2. Scale removal (rust) rate
≥98%;

7.3、清洗后的表面应形成良好的钝化保护膜，不应出现二次锈蚀和点蚀。
Surface should form a good protective film after cleaning. No secondary corrosion and pitting should be
formed.

7.4、表面形成良好的钝化保护膜，并不得出现二次锈蚀和点蚀，钝化膜转色时间不得少于 200s，达到优
良等级。
Surface should form a good protective film. No secondary corrosion and pitting should be formed. Color
transfer time of passivation film shall not be less than 200 s, with excellent grades.

7.5、固定设备上的阀门、仪表等不受到损伤。
Valves, meters and others on equipment should not be damaged.
8 施工管理和安全措施 CONSTRUCTION MANAGEMENT AND SAFETY
MEASURES
8.1、组织机构 organization

8.1.1、甲、乙双方共同组成“清洗工程指挥部”。
Organize cleaning engineering headquarters by party A and party B.

8.1.2、清洗现场应有甲方协调人员、乙方技术人员以及检修人员坚守岗位。
In cleaning scene, there are party A coordinator、party B technician and maintenance.

8.1.3、清洗现场及清洗设备设在附近清洗系统及废液中和槽处，并对现场进行围栏防护，设立醒目标志和
安全警告语。
Cleaning site and cleaning equipment should be near cleaning system and liquid neutralizing tank.
Cleaning site should be protected with fences, and set up eye-catching signs and safety warnings.

8.2、HSE 目标 HSE Goal

人身伤亡事故为零、设备事故为零、时间损失为零、排放达标、无相关方投诉、不污染环境。
No human casualty accident. No Equipment accident. Do not waste time. Meet discharge standards.
No complaints from the parties concerned. Do not pollute the environment.

8.3、安全措施 Safety measure

8.3.1、进入清洗施工现场的所有人员都必须登记并经过业主安全培训，并取得入场证。
All people in cleaning site should be signed and trained by owner, and get entry pass.

8.3.2、清洗现场的所有清洗工作必须遵守现场的安全程序，并由业主代表管理。
All cleaning work at the cleaning site must follow site safety procedures and be managed by the
owner's representative.

8.3.3、参加清洗的操作人员必须装备以下劳动保护用品：安全帽、耐酸工作服、防护眼镜、防护面罩、防
酸碱手套、劳保鞋。
Use labor protection appliances as follow: safety helmet, acid proof working suit, protective glasses,
face shield, acid and alkali resistant gloves and safety shoes.

8.3.4、清洗人员持证上岗。
Cleaning person should be employed with certificates.

8.3.5、清洗现场禁止明火作业和吸烟，禁止在清洗回路上进行其他作业。
No fire. No smoking. And do not other unrelated working in the site.

8.3.6、清洗现场有值班电工以随时消除设备缺陷。
Clean site with electrician on duty to eliminate equipment defects at any time.

8.3.7、操作人员必须穿戴防护用品上岗，安全员随时检查安全工作。
Do working with protective equipment. The safety officer checks the safety work at all times.

8.3.8、清洗现场和原料区域有明显标志，严禁无关人员进入，防止造成伤害。
The cleaning site and raw material area are clearly marked. It is strictly forbidden for irrelevant
personnel to enter to prevent injury.
 8.3.9、现场须配备专人进行安全监督，每天组织安全学习，施工人员发现安全隐患有权拒绝施工。
The site must be equipped with special personnel for safety supervision, every day to organize
safety learning, the construction staff found safety risks have the right to refuse the construction.

8.4、清洗应急计划书 the cleaning emergency plan

本次清洗过程中，容易发生砸伤、清洗液泄漏、人员摔伤等事故，针对施工作业中的事故险情制定了
相应的应急预案。施工现场必须有盛满清水的脸盆或桶，必须有急救箱，急救药品充足。
This cleaning process, prone to damage, cleaning fluid leakage, personnel fall injury and other
accidents, in view of the accident in the construction work to develop the corresponding emergency plan.
Construction site must be equipped with basin or bucket filled with clean water, there must be a first aid
box, first aid medicine is sufficient.

8.4.1、 砸伤 Crushing
作业人员若受到现场硬物砸伤、磕伤，情节较轻的将伤口消毒后包扎或使用创可贴即可 ，若流血不止
或造成骨折等情节严重的，派人将伤员送往厂方医务室治疗。
According to crushing, the measures are disinfection, band-aid and the clinic treatment.

8.4.2、泄漏 Leakage
清洗液泄漏：发现焊缝处或法兰连接处清洗液泄漏，先用桶或盆接收泄漏的液体，然后停泵，进行补
焊和紧法兰，必要时更换垫片。然后清扫干净。
Cleaning fluid leakage: if weld Spot or flange joint leak cleaning fluid, first person should receive the
liquid leakage with barrels or basin, and then stop the pump, repair welding and flange, replace the
gasket if necessary. Then clean up.

8.4.3、在投加清洗药剂时，操作人员佩戴好防护用品如防护眼、橡胶手套等，若药剂飞溅到脸部或者眼睛，
用清水冲洗就可。
When applying the cleaning agent, the operator should wear protective equipment such as rubber gloves,
etc. If the agent splashes onto the face or eyes, rinse with water.

8.5、化学清洗应急保护措施 Emergency protective measures of chemistry cleaning

8.5.1、关停清洗循环泵；Shut down cleaning circulation pump;

8.5.2、关闭清洗循环管线控制阀门;
Close control valves of the cleaning circulation pipeline;

8.5.3、迅速与项目指挥部、厂方联系，查找原因；
Quickly contact with the project headquarters and the manufacturer, in order to find the reason;

8.5.4、如两小时内无法恢复正常清洗工作，先打开系统排空；
If it is unable to work normally in two hours, open the system and empty it;

8.5.5、打开系统进行排液，排净系统内清洗液；
Open the system. Clean the liquid
9 交工验收 COMPLETION OF THE ACCEPTANCE
9.1.1 化学清洗完工后，先由我方自行检验，（化学清洗质量标准洗净率不低于 95%），
如局部有未清洗彻底的部分，由人工擦洗修复。
After the completion of chemical cleaning, we shall first conduct our own inspection (the cleaning rate
of chemical cleaning quality standard shall not be less than 95%). If there is any part that is not
completely cleaned, it shall be manually scrubbed and repaired.

9.1.2 自检合格后,再由船东检验验收，验收合格后我们马上对管路端头包装封存。
After the self inspection is qualified, the ship owner will inspect and accept it. After the acceptance is
qualified, we will pack and seal the end of the pipeline immediately.