Pipe prefabrication plays a vital role in modern industry, especially in the fields of petroleum, chemicals, construction and energy. Its manufacturing and processing process is complex and involves multiple links and process steps. This article will introduce in detail the various processes of pipe prefabrication manufacturing and processing in order to better understand and perform related work.
1. Design and planning
1.1 Engineering design
Detailed design drawings: Draw detailed pipeline prefabrication drawings based on project requirements and actual conditions at the construction site. These drawings include floor plans, piping sections, node diagrams, etc., which specify the size, shape and installation location of each piping component.
Material list: According to the design drawings, develop a detailed material list, including pipes, pipe fittings, valves, flanges and brackets, etc. This helps ensure that all necessary materials are available in a timely manner during the prefabrication process.
1.2 Planning and organization
Process planning: Develop the process flow for pipeline prefabrication and clarify the operating steps and precautions for each process. This includes cutting, welding, assembly and inspection.
Resource allocation: Allocate necessary manpower, equipment and materials to ensure the smooth progress of prefabrication work. This includes selecting a suitable prefabricated site, ensuring the availability of equipment and assigning the appropriate personnel to each operation.
2. Material preparation
2.1 Material procurement
Material selection: Select appropriate pipes and fittings according to design requirements. Commonly used pipes include carbon steel, stainless steel, alloy steel and plastic.
Quality inspection: Conduct quality inspection on purchased materials to ensure that they meet standards and specifications. This includes checking the appearance, dimensions and chemical composition of the material, among other things.
2.2 Material cutting
Cutting method: According to the size requirements of the design drawings, use appropriate cutting methods, such as gas cutting, plasma cutting, mechanical cutting, etc.
Precision control: Strictly control cutting size and angle to ensure cutting accuracy meets design requirements. Use precision measuring tools to make sure the dimensions of each section of pipe are within tolerance.
3. Pipe fitting processing
3.1 Blanking and prefabrication
Pipe fittings blanking: According to the requirements of the design drawings, pipes and pipe fittings are blanked. The accuracy of blanking directly affects the subsequent assembly and welding quality.
Prefabricated components: According to the prefabricated drawings, each pipe section, elbow, tee and other pipe fittings are prefabricated and assembled. Prefabrication requires special attention to the angles and lengths of individual components to ensure accuracy in the final assembly.
3.2 Pipe bending processing
Cold bending: bending pipes through mechanical cold bending equipment, suitable for small diameter and thin wall pipes.
Hot bending: The hot bending process is used for large diameter and thick wall pipes, and a pipe bending machine is used for heating and bending. This method ensures that the material properties of the pipe are not compromised during the bending process.
3.3 Flange installation
Flange welding: According to the design requirements, the flange is welded to the end of the pipe to ensure welding quality and sealing performance.
Flange correction: Check the flatness and verticality of the flange, and make corrections if necessary to ensure the accuracy of the flange connection.
4. Welding
4.1 Welding process selection
Welding method: According to the pipe material and design requirements, select the appropriate welding method, such as manual arc welding, gas shielded welding (MIG/TIG), submerged arc welding, etc.
Welding process regulations: Develop detailed welding process regulations, clarify welding parameters, welding sequence and welding inspection requirements.
4.2 Welding operations
Welding implementation: Carry out welding operations in accordance with the welding process regulations to ensure that the welding quality meets the requirements.
Weld inspection: Conduct visual inspection and non-destructive testing of welds, such as ultrasonic testing, radiographic testing, etc., to ensure weld quality.
5. Quality Control
5.1 Dimensional inspection
Dimensional measurement: Use measuring tools to measure the dimensions of prefabricated pipe components to ensure that the dimensions meet the design requirements.
Tolerance control: Strictly control dimensional tolerances to ensure interchangeability and assembly accuracy of pipeline components.
5.2 Appearance inspection
Appearance quality: Check the smoothness of the pipe surface, the appearance of the welds and the integrity of the anti-corrosion coating.
Defect treatment: Process and repair the discovered appearance defects to ensure that the appearance quality meets the requirements.
5.3 Stress testing
Hydrostatic test: Perform a hydrostatic test on the prefabricated pipeline components to verify their pressure-bearing capacity and sealing performance.
Air pressure test: For specific medium transportation pipelines, air pressure tests can be conducted to ensure their air tightness.
6. Surface treatment
6.1 Anti-corrosion treatment
Surface cleaning: remove rust and clean the surface of the pipeline to ensure the adhesion of the anti-corrosion coating.
Coating spraying: According to the design requirements, spray the anti-corrosion coating to ensure the thickness and uniformity of the coating.
6.2 Insulation treatment
Insulation material selection: According to the medium temperature and environmental conditions, select appropriate insulation materials, such as glass wool, rock wool, polyurethane, etc.
Insulation construction: The pipes are covered with an insulation layer to ensure the insulation effect.
7. Assembly of prefabricated components
7.1 Component assembly
Component splicing: According to the prefabricated drawings, assemble and splice each prefabricated pipe section and pipe fittings to ensure assembly accuracy.
Connection and fixation: Use welding, flange connection or threaded connection to fix the prefabricated components.
7.2 Bracket installation
Bracket arrangement: According to the design requirements, install pipe brackets to ensure the support and fixation of the pipes.
Bracket adjustment: Adjust the height and position of the bracket to ensure that the straightness and slope of the pipe meet the design requirements.
8. On-site installation
8.1 Transportation and lifting
Transportation: Transport the prefabricated pipe components to the installation site, paying attention to protecting the pipe surface and interfaces.
Hoisting: Use lifting equipment to hoist the pipeline components to ensure safety and stability during the hoisting process.
8.2 On-site connection
Interface treatment: Treat the on-site interface to ensure it is clean and smooth.
On-site welding: Weld on-site interfaces to ensure welding quality and sealing performance.
8.3 Debugging and acceptance
System debugging: debug the installed pipeline system to ensure that the system operates normally.
Acceptance testing: Carry out system acceptance testing to ensure that the pipeline system meets the design requirements and operating specifications.