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1、余热锅炉酸洗施工方案指导目录L工程介绍 Introduction/scope22 .编制依据 Basis of compilation33 .施工前准备 Essential conditions and preparations before the work44 .施工方法 Construction method85 . 质量标准要求 Quality standard requirement 156 .作业安全要求及环境要求 Safety requirement and environment condition for the work167附录 Appendix22219X6)oConn
2、ect the boiler LP/IP/HP economizer drain pipe and evaporator drain pipe to the cleaning acid return (discharge) main pipe (219X6)。4. 2.1. 6将启动排水管道连接到清洗水箱；将汽包内启动排水管道加高至清洗液位.Connect the start drain pipe to the cleaning water tank; raise the start drain pipe in the steam drum to the cleaning liquid lev
3、el.4.2. 1.7将再循环水泵进出口管道连接到水箱，并安装阀门。Connect the inlet and outlet pipes of the recirculation water pump to the water tank and install valves.4.3. 1.8将高、中、低压汽包就地液位计液面侧入口管断开加装临时液位计，高、中、低压 汽包内液位分别控制中心线以上：350mm + 50mm 200mm50mm、400mm50mm。Disconnect HP/IP/LP drum local liquid level side inlet and install te
4、mporary liquid level. The liquid level in the HP/IP/LP drums are respectively controlled above the center line:HP drum: 350mm50mm,IP drum :200mm50mm,LP drum:400mm + 50mm.4. 2. 2 临时系统安装的要求:Installation of temporary system4. 2. 2.1安装临时清洗系统时，管道内不得有砂石及其他杂物。安装前用压缩空气进行吹扫。 There shall be no sand and other
5、debris inside the pipe when installing temporary cleaning system. The temporary pipes shall be cleaned vide air blowing before installationo4. 2. 2. 2临时清洗管道朝排水方向的倾斜度,不得小于l/200o The temporary cleaning pipe shall slope to drainage direction and shall not less than 1/200.4. 2. 2. 3在安装清洗泵进出口管道时，应考虑热补偿措施
6、，不使水泵承受过大的推力。Consider heat compensation measure when install cleaning pump outlet pipe, the water pump shall not bear too much stress.4. 2. 2. 4临时系统中安装的温度、压力，应经校验合格。The thermal, pressure in temporary system shall be calibrated.4. 2. 2. 5临时系统管道安装前用压缩空气吹扫，管内杂物一定要清理干净，并用手电筒光照 确认无异物，以免损坏清洗泵和阀门。The tempo
7、rary pipes shall be cleaned vide air blowing before installation. Confirm there it is clean inside the pump in order not to damage cleaning pump and valve.临时管道固定良好，临时管道支架用型钢固定良好Temporary pipe shall be well fixed and temporary pipe support shall be well fixed by structural steel angle iron.4. 2. 2. 7
8、临时管道安装完成后，进行1. 5倍的压力试验。Hydraulic pressure test (1. 5 times the static head) to the temporary lines will be done.4. 2. 2. 8临时管道施工完成后进行保温。Insulation will be installed after temporary pipe completed.4. 2. 2. 9在清洗过程中，当停电或者清洗泵跳闸时，立刻关闭回酸母管上的阀门，启动备用 电源进行供电，启动清洗泵进行清洗。During the cleaning process, when the po
9、wer is cut off or the cleaning pump trips, the valve on the acid return pipe is immediately closed, the backup power supply is started for power supply, and the cleaning pump is started for cleaning.5. 2.2. 10在清洗前，向HP/IP/LP过热器内充满保护液，保护液PH值：9.5-10.Before cleaning, fill the HP/IP/LP superheater with p
10、rotective liquid, the PH value of protective liquid: 9.5-10.Before cleaning, fill the superheater with protective liquid, the PH value of protective liquid: 9.5-10.6. 2. 3 化学清洗步骤 Chemical cleaning procedure2. 3. 1 加药方式 Dosing Method在加药之前，根据系统容积计算所需要的药品量。向清洗箱加注固体药品时，采用人工的 方式；加注液体药品时，采用泵和人工的方式。Before
11、dosing, calculate the required medicine quantity according to the system volume. When filling solid medicines into the cleaning tank, manual methods are used; when filling liquid medicines, pumps and manual methods are used.7. 2. 3. 2 水冲洗：Water flushing分别按照回路高、中、低压进行系统水冲洗 Perform system water flushi
12、ng according to HP/IP/LP system.冲洗终点：出水基本澄清，无杂物，预计用水量2400吨。Flushing terminal: The water coming out is impurity free. Estimated water consumption is 2400T.8. 炉前系统水冲洗、碱洗、碱洗后水冲洗The system in front of the furnace is rinsed with water, alkaline washing, and water rinse after alkaline washinga）水冲洗;透明无颗粒 R
13、inse with water; transparent without particlesb）炉前系统冲洗完成后，开始加入双氧水进行清洗，双氧水浓度0.05%0.1临循环3 小时，浸泡10小时，完成后直接排放。After the flushing is completed, start to add H202 for cleaning, the concentration of H202 is 0. 05% -0.1%, circulate for 3 hours, and soak for 10 hours, Discharge directly after completion.温度 t
14、emperature：常温 Room temperaturec）碱洗后水冲洗：透明无颗粒，PH6Rinse with water after alkaline washing: transparent without particles, PH6 4. 2. 3. 4 EDTA 酸洗步骤/EDTA pickling step1）待水温在75C,清洗系统运行稳定后，在清洗箱中加入需要量的缓蚀剂和还原剂，加入 炉内循环lh左右。After the water temperature is at 75 and the cleaning system runs stably, add the requ
15、ired amount of corrosion inhibitor and reducing agent to the cleaning box, and add it to the furnace for circulation for about 1 hour.2）缓蚀剂和还原剂循环均匀，准备加酸。Corrosion inhibitor and reducing agent circulate evenly, ready to add acid3） EDTA 镂盐清洗：EDTA ammonium salt cleaning:EDTA 镂盐清洗工艺参数： EDTA ammonium sal
16、t cleaning process parameters:a） EDTA镂盐：36%缓释剂：0.30. 4%还原剂：15002000mg/L消泡剂：适量 温度：85时间：W24小时加药流程：通过加药泵将药品从药桶内抽入自制的加药装置内，通过酸洗泵运行时回路管内 负压注入管道通入清洗水箱进行加药。建立炉本体系统循环回路，继续升温，当温度升至75左右时，调节蒸汽加热阀门维持水 温士75左右，先加缓蚀剂，控制浓度在0. 30. 4%,循环60分钟后再添加EDTA,控制浓度 在36%,并添加氨水调整pH值在4. 55. 5之间，同时加入适量还原剂，根据泡沫大小加 入适量消泡剂。加药完毕后，持续升温，
17、控制贮水箱正常水位，当温度达到85时，维持 温度即可。清洗过程中启动分离器顶上排气管处于开启状态，清洗开始每小时化验一次，待 出口全铁离子总量23次取样化验基本不变，残余EDTA浓度维持在0.5%以上，参考监视管 清洗效果（取样合格后则进行拆开检查），可以考虑结束清洗。EDTA ammonium salt: 36% slow release agent: 0. 30. 4% reducing agent: 15002000mg/L a)Defoamer: appropriate amount Temperature: 85 Time: W24 hoursDosing process: the
18、drug is pumped from the drug barrel into the self-made closing device through the dosing pump, and the negative pressure in the loop pipe is injected into the cleaning water tank through the negative pressure in the loop pipe when the pickling pump is running for dosing.Establish a circulation loop
19、of the furnace body system and continue to heat up. When the temperature rises to about 75 C, adjust the steam heating valve to maintain the water temperature at about 75 C, add corrosion inhibitor first, control the concentration at 0. 3-0.4%, and add EDTA after 60 minutes of circulation , Control
20、the concentration at 3 to 6%, and add ammonia water to adjust the pH value between 4. 5 and 5. 5. At the same time, add an appropriate amount of reducing agent, and add an appropriate amount of defoamer according to the size of the foam. After the dosing is completed, continue to increase the temper
21、ature to control the normal water level of the water storage tank, and maintain the temperature when the temperature reaches 850 C. During the cleaning process, the exhaust pipe on the top of the starter separator is in the open state, and the cleaning starts to be tested once an hour. The total amo
22、unt of iron ions at the outlet is basically unchanged for 2 to 3 times, and the residual EDTA concentration is maintained above 0. 5%. Refer to monitoring The tube cleaning effect (disassemble and inspect after the sampling is qualified), you can consider ending the cleaning.b)专屯化 Passivation清洗完成后，仍
23、按清洗阶段的循环方式运行，通过加药装置加入氨水快速调整PH至8.59.5, 维持温度85,开始计时，钝化46小时。钝化结束后，停清洗泵。然后通过省煤器、蒸 发器下集箱排酸管道进行热炉快速放水。同时打开各路疏水排放。减少死区、盲区的沉积物。 至此，整个清洗过程结束。b)After the cleaning is completed, it still runs in the cycle of the cleaning stage. Add ammonia water through the dosing device to quickly adjust the PH to 8.59.5, mai
24、ntain the temperature 85, start timing, and passivation for 46 hours. After the passivation is over, stop the cleaning pump.Then through the economizer and the evaporator lower header acid discharge pipeline for rapid water discharge from the hot furnace. At the same time, open all drainage channels
25、. Reduce the dead zone and the sediment in the blind zone.At this point, the entire cleaning process is over.423.5化学清洗结束后的工作：迅速打开汽包两边人孔，挂轴流风机通风，同时也应尽快打 开与下联箱及省煤器相连的阀门或接口，使锅炉处于自然通风状态。Open the manhole on both side of drum, put axial fan for ventilation. And open the valve or connector which connects t
26、o low header and economizer as early as possible. Make the boiler at condition of natural ventilation.4.2.3.6 最终检查 final inspection打开汽包人孔，取出试片，进行称重测量，计算腐蚀量和腐蚀速率。在汽包人孔两端悬挂轴流风机进行通风，待冷却后进行汽包内表面的检查，钝化膜良好。 切割临时管道，检查下部管道内表面，钝化膜形成良好。Open the manhole of the drum, take out the test piece, carry out weighing
27、measurement, and calculate the corrosion amount and corrosion rate.Axial fans are hung at both ends of the manhole of the steam drum for ventilation. After cooling, the inner surface of the steam drum is inspected, and the passivation film is good.Cut the temporary pipeline, check the inner surface
28、of the lower pipeline, and the passivation film has formed well.4.2.3.7 在汽包内表面检查完成后，根据图纸安装汽包内部装置。封闭汽包人孔前进行内部检 查，确保内部无异物。After the inspection of the inner surface of the drum is completed, install the internals of the drum according to the drawings. Before closing the manhole of the drum, perform an
29、internal inspection to ensure that there is no foreign matter inside.4.2.3.8 废液的处理排放：Disposal of waste liquid酸洗结束后，直接将化学清洗废液排入废水池，排放标准符合孟加拉国家水污染物排放标 准、孟加拉项目燃气热电工程环境影响报告书及补充报告书的有关规定。After the pickling is completed, the chemical cleaning waste liquid is directly discharged into the waste water tank, a
30、nd the discharge standard complies with the relevant regulations of the Bangladesh National Water Pollutant Discharge Standard1, the Environmental Impact Report of the Gas-fired Thermal Power Project in Bangladesh and the nSupplementary Report.5. 质量标准要求 Quality standards and requirements5. 1 质量目标 Qu
31、ality objectives清洗后的金属表面应清洁，基本上无残留氧化物和焊渣，无明显金属粗晶析出的过洗 现象，不应有镀铜现象。After cleaning the metal surface should be clean, in general, there should be no oxide residuals and welding slag, no visible signs of excessive cleaning and coarse metal precipitation, and no copper plating pHenomenon.5. 1. 2腐蚀指示片安装在汽
32、包内部两端，数量2片，在进酸管和回酸管监视管内各加2片指 示片，腐蚀总量要小于80g/m2。The corrosion indicator plates are installed at both ends inside the steam drum, quantity is 2, adding two pieces of corrosion indicator plates at both acid inlet & acid return pipe, the total corrosion amount is less than 80g/m2.5.1.3 清洗后的表面应形成良好的钝化保护膜，
33、不应出现二次锈和点蚀。After cleaning, a good passivation protective film should be formed on the surface, and secondary rust and pitting corrosion should not occur.5.1.4 固定设备上的阀门、仪表等不应受到损伤。Valves, instruments, etc. on fixed equipment should not be damaged.5. 1.5取样检验：在进酸母管上加监视管旁路，指示片装在监视管内，酸洗结束后拆下监视 管检验清洗效果。Sam
34、pling test: A monitoring pipe bypass is added to the acid feed pipe, the indicator is installed in the monitoring pipe, and the monitoring pipe is removed after acid washing is completed to check the cleaning effect.表观检查：打开各汽包人孔、目视汽包内壁，检查清洗质量；汽包内有明显的水位分 界线，水侧呈钢灰色或者褐色。Visual inspection: Open the manh
35、oles on each steam drum, visually check the inner wall of the steam drum to check the cleaning quality. Check if there is a visible water level dividing line in the steam drum and whether the steel surface in the water side has grey or brown color.5. 2 废液处理及保养工作 Waste liquid treatment and maintenanc
36、e5. 2. 1 清洗废液的排放:Waste liquid draining after cleaning:化学清洗废液用临时管道直接排入酸碱废液池中，然后有孟加拉国家政府环保部门发放有危化许可证的废水处理公司运输处理，达标排放。最后废液处理公司出具当地环保部门认 可的处理报告单.The chemical cleaning waste liquid is directly discharged into the acid-base waste liquid pool through a temporary pipeline, and then transported and processed
37、 by a wastewater treatment company with a hazardous chemical license issued by the environmental protection department of the Bangladesh national government, and the discharge meets the standard. Finally, the waste liquid treatment company issued a treatment report approved by the local environmenta
38、l protection department.5. 2. 2若清洗后距锅炉再次上水时间超过二十天，锅炉应采取充氮保养。If it takes more than 20 days to refill the HRSG after cleaning, Boiler should be nitrogen-filled maintenance.5. 2. 3 化学清洗监督项目 Monitoring items of chemical cleaning序号No工序Process介质Medium浓度 Concentra tion监督项目 Monitoring item控制范围Control scope备
39、注 Comment1水冲洗 Water washing除盐水 Demineraliz ed watepH:7左右 pH: around 7澄清度Clarity level澄清 无机械颗粒悬浮 物 clarify No mechanical particle suspensionr随时取样，30分钟一次 Sampling at random times, 30 minutes2EDTA 酸洗 EDTA acid cleaning缓蚀剂 还原剂EDTACorrosion inhibitor reducing agent EDTA0. 3% 0. 04-0. 0 5% 3-6% PH4. 5-5.5
40、温度 temperature EDTA浓度EDTA concentration 铁离子含量 Iron ion content PH4. 5-5. 5805 , 含量 content 5% 最后两次取样化 验铁离子稳定，快 速排放酸液The last two samples tested the stability of iron ions, rapid discharge of acid时间8-10小时，终点 为酸浓度、总铁浓度 基本稳定，时间24h, 取样间隔60分钟 8-10hour interval, final acid concentration; total iron concen
41、tration is stable in 24 hours; samples to be collected every 60 minutes3钝化 Passivation氨水 ammonia hydrogen peroxide ammonia温度 temperature, pH85 时间6小时6 hours interval6. HSE (健康、安全、环境)及消防保障措施HSE (Health, safety, environment) and fire protection measures6. 1 危险点及其控制措 Dangerous incidents and control meas
42、ures序号No.危险点描述 Dangerous incident description危险因素 Risk factor控制措施Control measure责任人 Responsible person1脚手架上检查人1.挤压碰伤1.脚手架必须按规程搭设经验收合安全员施工监护人序号0.危险点描述 Dangerous incident description危险因素 Risk factor控制措施Control measure责任人 Responsible person员坠落Person doing the inspection falls from the scaffolds2 .高空坠落3
43、 .高空落物伤 人。1. Squeeze and bruise2. Fallfromheights3. Injury by, falling objects格方可使用；2.检查人员必须正确使用安全带；1. Scaffolds must be built in compliance with regulations and used after being approved through inspection.2. Inspection personnel must properly use the safety beltHSE officer and construction work gu
44、ardian2酸液烧伤、 中毒及对设备伤 害Acid burn, poisoning, equipment damage1 .酸液对人员灼 伤2 .酸液对设备伤 害1 .Personal injuries due to acid burn2 .Equipmentdamage due to acid burn1 .按方案加药人员穿防酸碱服、戴耐 酸胶手套、防毒面具等防护用品， 现场配备防灼伤急救药品。2 .按方案进行必要的隔离。1. In compliance with the method statement, Acid and alkali proof clothes, acid resis
45、tant rubber gloves and gas mask must be warn and acid burn first-aid kit must be present at the construction site.2. In compliance with method statement, necessary quarantine measures must be taken.安全员施工监护人 USE officer and construction work guardian3防止触电 Electric shock prevention漏电伤害 injuries caused
46、 bycurrentleaking设备启动前认真检查供电开关,就地 电源盘柜和电机绝缘及接线。Thoroughly check power supply switch, local power panel and motor insulation and earth grounding before switching on the equipment.安全员施工监护人 USE officer and construction work guardian4酸洗泄漏伤害 injury caused by chemical cleaning leaking人员伤害Personnel injury1
47、 .泄露时暂停设备运行，及时消除缺 陷，用石灰石对泄露的酸液进行中 和。2 .严禁在法兰盘侧面和堵头处逗 留。1. Temporarily cease the equipment operation and remove the defects when there is leakage, neutralize the leaked acid with limestone.2. It is strictly forbidden to stay beside the flange plate and the plug.安全员施工监护人 HSE officer and construction w
48、ork guardian5意外伤害 Accidental injury1 .人员伤害2 .设备伤害1 .Personnel injury2 .Equipmentdamage挂警示牌、警戒线，并有专人监护 Install warning signs and safety tape, designate a guardian person安全员施工监护人 HSE officer and construction work guardian6.2 防暑降温管理 Heatstroke prevention序号0.危险点描述 Dangerous incident description危险因素 Risk factor控制措施Control measure责任人 Responsible person6废液排放 Waste liquid discharge环境污染 Environment pollut