Stainless Steel Pipe Pickled and Passivated Procedure.docx
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StainlessSteelPipePickledandPassivatedProcedure
TABLEOFCONTENTS
1GENERAL3
2PICKLEDANDPASSIVATEDPROCESSBEFOREINSTALLINGPIPE4
3ThestainlesssteelpipepickledandpassivatedofthePartSection11
1GENERAL总述
1.1Scope范围
ThisproceduredefinestheminimumtechnicalrequirementsforthepickledandpassivatedofstainlesssteelpipingtobeinstalledonoffshoreLNGfacilities.ThestainlesssteelpipingincludesallFLRSUprocessandutilitystainlesssteelmaterialpiping.
本程序详细说明了海上LNG装置不锈钢管线酸洗钝化的最低技术要求。
不锈钢管线包含了所有安装在FLRSU上的工艺不锈钢管线及公用工程不锈钢材质管线。
1.2Applicabledocuments应用的标准和规范
1.2.1Alltestingshallbeinaccordancewiththestandardandspecification.
ASMEB31.3PROCESSPIPING
工艺管道规范
APIRP14ERecommendedPracticeforDesignandInstallationofOffshoreProductionPlatformPipingSystems
海上生产平台管道系统设计和安装的推荐做法
DD-SPC-WHPA（MDR）-PI-0006SpecificationForPipingTesting
177188-0000-P0106Lineschedule管线数据表
02528_TH32_DSH_5106_0001PipingInstallation管线安装
ASTM-A967-2005StandardSpecificationforChemicalPassivationTreatmentsforStainlessSteelParts
不锈钢部件化学钝化处理规范
1.3ProcessPrincipleandPurpose工艺原理及目的
Themainpurposeofstainlesssteelpipepickledandpassivatedistoetchthesurfaceofstainlesssteelslightlyforremovingsurfacedirt,theinvisibletemperingcolorsandsomefreeironions,sothatthesurfaceenricheschromiumelement.Afterthepickledandpassivatedtreatment,itisveryconducivetoformhighqualitypassivationlayerofprotection.Theapplicationofacidpicklingandpassivatedforstainlesssteelisbasedonthegiventemperature,exposuretimetofinishaccordingtothestainlesssteelmaterialrequirement.Needlesstosay,inordertoreducethedamageofpipelinesystem,thetoolsofriskandreducetheharmtothehumanbody,thisworkshouldbedonebytheProfessionalCompany.
不锈钢管线酸洗钝化的主要目的是把不锈钢表面轻微地蚀刻掉一层，去除表面所有无关的金属污物、残留的视觉上看不到的回火颜色及一些游离的铁离子，使表面富集铬元素。
酸洗钝化过后不锈钢表面干净、富铬，非常有利于形成高质量的钝化保护层。
酸洗钝化应用酸洗液钝化液按照不锈钢材料的要求在给定的温度、曝光时间下完成。
毋庸置疑，这项工作应由专业公司来完成，以降低损坏管子和工具的风险，减少对人体的伤害。
Stainlesssteelpipespoolwillhavesomedefectsintheprocessofearlyprefabrication,suchasrust,oxidationfilmandsoon.Inordertoensurethatpipespoolmeasureuptosystemrequirementsafterinstallingonboardinashipandbeforedelivery,itneedsbepickledandpassivatedafterprefabrication.
不锈钢管段在预制初期和预制过程中会产生一些锈迹、氧化膜等瑕疵。
为保证管段在船上安装后和船舶交付前达到系统要求，需要对预制后的管段进行酸洗钝化处理.
Theprojectincludestwoaspectsgenerally:
Ontheonehand,thefinishedpipespoolneedtobepickledandpassivatedtreatmentaftertheprefabrication;
Ontheotherhand,thepipeweldingjointneedtobepickledandpassivatedtreatmentonoutersurfaceafterpipeinstallation.
本项目简单的说，就是有两个方面：
一方面是成品管段在预制结束后需要酸洗钝化处理；
另一方面就是现场安装后的管线焊口外表面的酸洗钝化处理。
2PICKLEDANDPASSIVATEDPROCESSBEFOREINSTALLINGPIPE安装前管段酸洗钝化工艺
2.1ConstructionPreparation施工准备
∙Theacidpickledandpassivatedchemicals,formulaandotherequipment.
酸洗钝化的化学药品、配方等设施。
∙Equipment,machinesandtools:
设备机具:
Apickledandpassivatedtank:
Degreasingtank,pickledandpassivatedtank;
酸洗钝化槽：
分别为脱脂除油槽、酸洗、钝化槽；
2.2LaborOrganization劳动组织
2.2.1Accordingtotheprojectrequirements,Thepickling&passivationvendormustsupplyitsorganizationalchartandreportstoclientfortherecordduringtheperiodofpicklingandpassivatingtreatment.Accordingtothequantitiesofpicklingandpassivating,thepicklingandpassivatingworkshouldbeoperatedbythoseexperiencedchemicalpicklingandpassivatingworkersandprofessionaloperationteam.
根据该项目要求在进行酸洗钝化工期期间，分包方必须有完善的组织架构，并上报给业主备案：
根据酸洗钝化工程量，原则上应组织经历过化学酸洗钝化并富有一定实践经验的操作工人组成专业施工小组进行酸洗钝化工作。
2.2.2Ensurethepickling&passivatingtreatmentforcontinuity,thesiteworkermustbeondutywhenpickledandpassivated.Accordingtotheneedofsiteoperation,itispersonnelfull-timeworkinprinciple,theworkmustbeinlinewiththeoperationrequirementsofproject.
为保征酸洗钝化过程工作的连续性，酸洗钝化时保证酸洗钝化现场人员值班作业。
根据现场施工需要，原则上施工人员全日制工作制，其工作进度必须满足项目施工要求。
2.3HandoveroftheFinishedPipe成品管的交接
2.3.1WISONshallsupplypipespoolfinishedandtested（includingvisibleinspected,andNDT）andfillsoutaspoolreceipt.Andthensendstopickled&passivatedsitetohaveahandoverwiththevendor,bothpartiesneedtosignthereceiptforconfirmation.
WISON将制造完工并经检测合格（含外观检验、无损检验）后的成品管段填写管段交接单送酸洗钝化场地与分包方进行交接，双方需在交接单上签字确认。
2.3.2WISONshallcheckwhethereverypipespoolmeasureuptotherequirementsofpickledandpassivatedtechnologyornotduringthepretreatment,iftheoutersurfaceofthepipefittingqualityisfound（suchasweldingslag,splash,pipesurfaceproblem,etc.）torepairweldingandgrinding,WISONneedsmakesecondarytreatmentandsendthemtovendorforregularsurfacetreatment.
WISON在预处理时需对每根管段是否满足酸洗钝化工艺要求进行检查，如发现管段的外表面质量（如焊缝两侧的焊渣、飞溅物是否清理干净，管段表面是否存在凹坑和划伤等）存在缺陷需要补焊和打磨的，需WISON进行二次处理，处理合格后再送分包方进行常规的表面处理。
2.4ThePickledandpassivatedProceduresareasFollows:
酸洗钝化作业程序如下：
Pretreatment（foreignbodyremovalofweldingpartisoperatedbyWISON）→waterrinse→degrease→waterrinse→pickled→waterrinse→passivated→waterrinse→neutralized→hotwaterrinse→packagingarchive.
预处理（焊接部位异物清除由WISON施工）→水冲洗→脱脂→水冲洗→酸洗→水冲洗→钝化→水冲洗→中和→热水冲洗→包装封存。
Pipespoolareonthebasisofpickledandpassivatedbeforeinstallationtoimmersepickledandpassivatedfordifferentdevices,pipelinesandcomponentsparts.ImmersionpicklingbluntincludesdegreasingprocessandPickledandpassivatedprocess.
管段安装前以浸泡酸洗钝化为基准，分别对不同介质设备、管道、组成件等进行浸泡酸洗钝化，浸泡酸洗钝化分脱脂工序和酸洗钝化工序。
Thoseequipmentthatcannotbepickledandpassivatedtankorpipespoolcanbeusedtowipepickledandpassivatedorsmearpassivationpastetreatment.
对于无法进入酸洗钝化槽的设备或管段可采用擦拭酸洗钝化或涂布钝化膏处理。
2.5Pretreatment:
预处理：
2.5.1Cleantheforeignbodyonbothsidesofweld,usestainlesssteelwirebrush,stainlesssteelshovelorgrindingwheeltoclearout,usecleanwater（contentofchlorideioninwaterlessthan25mg/l）torinse;
清除焊缝两侧异物，应用不锈钢丝刷、不锈钢钢铲或砂轮清除，清除完毕后用净水（水中氯离子含量不超过25mg/l）冲刷干净；
2.5.2Theoxideskinafterhotworkingpiecesusesmechanicalsandwashingtocleanout,thesandmustbepuresilicaoralumina;
对经过热加工件的氧化皮用机械冲砂方式清除，砂必须是纯硅或氧化铝；
2.5.3Theoilstainthroughthesurfaceofpipespoolusespipecleanertorinse.Whentheoilstainisserious,useaqueousalkaliwith3-5%consistencytocleanandthenpurewatertorinseout.
对管段的机加工表面的油污，应用清洗剂进行清洗，当油污严重时则用3-5%的碱溶液将油污清除，再用净水冲洗干净；
2.5.4Afterpreliminarypretreatmentofpipespooluseabsorbentcottonclothtowipe,forlong-distancefinishedpipesneeduseabsorbentcottonballtowipeagainandagain.
对于经过初步预处理过的管段再用脱脂棉布擦拭，对于长距离的成品管道需要采用脱脂棉团，反复涂布擦拭。
2.6WaterWash:
水冲洗：
Usehigh-pressurewaterjetequipmenttowashthepickledandpassivatedequipmentorthesurfaceoftheequipmenttorinsethesurfacesuspendedcontaminantsofpipelineandkeeppipelinewet;
采用高压水射流设备冲洗即将酸洗钝化过的设备或管道的表面，目的是冲洗掉设备或管道表面悬浮的污染物及设备或管道润湿作用；
2.7Degreasing脱脂
EquipmentofPickledandpassivatedandpipespoolareputintothegrooveandsoakedfor30minutestodegrease（thespecifictimeaccordingtomeetthepassivationmembranethicknessrequirement）.
所需酸洗钝化的设备及管段吊装放入槽内，脱脂浸泡时间为30分钟（具体时间按满足钝化膜的厚度要求为准）。
2.8WaterRinse水冲洗
Usefreshwatershallbeusedasthemediumofwaterrinse（chlorineioncontentisnotmorethan25mg/linthewater）.Throughrinsingthedegreasingequipmentandpipespoolwiththewaterpressure,thePHvaluerequirementonthesurfaceofequipmentandpipespoolreachestherangebetweensixandeight.
可采用淡水作为水冲洗介质（水中氯离子含量不超过25mg/l），通过水压不断冲洗已经脱脂好的设备及管段，冲洗后的设备或管道表面要求为PH值达到6-8范围内。
2.9Pickled：
酸洗：
Accordingtotechnologyrequirement,usepickledpasteandpickledtanksoak.
根据工艺要求，可以采用酸洗膏及酸洗槽浸泡。
PickledTankSoaking:
Theequipmentorpipespoolfittingsareputintothegroovefor30minutes（thespecifictimeaccordingtocleanupthepipespoolsurfacedirtycompletely）,andthentakethemoutforrinsing.Aftertheacidconsistencyreducesinthetank,itshallbeaddedacidliquid.
酸洗槽浸泡处理：
设备或管段进入槽内30分钟后（具体时间以彻底清除表面污物为准），取出设备或管段进行水冲洗。
当槽内酸浓度降低后，需要补充酸洗剂。
2.10WaterWash
Usedematerializedwater（contentofchlorideionlessthan25mg/linwater）asthewaterrinsemedium.Throughrinsingthedegreasingequipmentandpipespoolwiththewaterpressure,requirementsofthesurface:
PHvaluereachestherangebetween6and8.
水冲洗：
采用除盐水（水中氯离子含量不超过25mg/l）作为水冲洗介质，通过水压不断冲洗已经酸洗钝化好的设备，冲洗后的设备或管段表面要求：
PH值达到6-8范围内。
2.11Passivated：
钝化：
Accordingtotechnologyrequirement,usepassivatedtanksoaked.
根据工艺要求，可以采用钝化槽浸泡。
PassivatedTankSoaked:
Theequipmentorpipespoolareputintothegroovefor30minutes（thespecifictimeaccordingtopassivatedquality）,andthentakethemoutforrinsing.
钝化槽浸泡处理：
设备或管段进入槽内30分钟后（具体时间以满足钝化效果为准），取出设备或管段进行水冲洗。
2.12WaterWash水冲洗
Usedematerializedwater（contentofchlorideionlessthan25mg/linwater）asthewaterrinsemedium.Throughrinsingthedegreasingequipmentandpipespoolwiththewaterpressure,requirementsofthesurface:
PHvaluereachestherangebetween6and8。
水冲洗：
采用除盐水（水中氯离子含量不超过25mg/l）作为水冲洗介质，通过水压不断冲洗已经酸洗钝化好的设备，冲洗后的设备或管段表面要求：
PH值达到6-8范围内。
2.13Neutralized中和
Thepipespoolshallbedoneneutralizedafterpassivatedtoavoidanypipesurfacepassivatedliquid.Itshallbeusedweakalkalisoakedabout1min.Andthenusinghotwatersoakedinordertodry.
为避免不锈钢表面有残留的钝化液,造成以后的腐蚀,钝化后应在弱碱溶液中于室温下中和处理1min，再用热水洗便于干燥。
2.14PackagingArchive:
TheequipmentorpipespoolneedbeprotectednecessarilyafterPickledandpassivatedandsurfacepaintequipment.Accordingtovendorprotectionways,vendorprovidespackagingprotectiontechnologyandequipmenttoWISONforconfirmation（donotuseasbestosmaterial）.OnceWISONconfirms,vendorwillprovidepackagingprotectionforeverypipespoolandmarksthesignwith"picklingandpassivatingquali
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