Industrial pipelines are generally different from pipelines in civil construction projects, with stricter requirements in terms of material acceptance, connection methods, and installation quality. I have been responsible for the installation and management of industrial pipelines for about 10 years. Let me take a look.

First, let's talk about the basic procedures, including material acceptance, sandblasting for rust removal and corrosion prevention, material cutting, prefabricated welding, on-site support installation, on-site pipeline installation, integrity inspection, pressure test (air tightness test), insulation and cooling, blowing, trial operation, factory identification color, and data transfer.

Material acceptance is generally witnessed by the construction unit, Party A, and the supervisor. For pipe materials, specifications, dimensions, wall thickness, quality certification documents, certificates of conformity, etc. are generally inspected. Each industry has different forms, and acceptance is completed according to the acceptance standards. The form data is filled in based on actual measurement data, and then the three parties sign the acceptance opinions. Qualified products can be used, while unqualified products enter the unqualified product processing program.

Underground pipelines generally have anti-corrosion requirements, which involve rust removal, some by shot blasting, some by hand. This depends on the design requirements. After reaching the rust removal level, anti-corrosion construction can be carried out after the supervision acceptance is completed. There are general types, reinforced types, and special reinforced types. The entire pipe or longer pipes will be anti-corrosion treated, and the welding joints will be left at the site for additional anti-corrosion treatment after welding.

Cutting and prefabrication are the tasks completed in the prefabrication yard. The management team will mark the weld joint based on the drawing fracture, cut the material, and hand it over to the welder for welding. Here, it should be noted that industrial pipelines are generally connected by welding due to the properties of the medium and pressure. The welding process is evaluated based on the material and the on-site environment. After the prefabrication is completed, the materials are set aside for on-site installation.

Before on-site pipeline installation, various types of brackets such as spring brackets, fixed brackets, sliding brackets, etc. will be installed. The installation method is also the same, with pre embedded plate welding and expansion bolt installation, depending on the pipeline conditions and on-site conditions. Some pipelines require a pipe gallery, so steel structure pipe galleries or underground pipe galleries will be constructed first, and after completion, on-site pipeline installation will be carried out.

On site pipeline installation generally involves transporting prefabricated pipelines to the site, placing them according to the prefabrication numbers based on the drawings, and then welding them by welders. The welding process for each type of pipeline material is different, and the requirements for welders and environments are also different. Of course, the welding materials are also different. It depends on the situation.

After the pipeline installation is completed, a completeness check is usually carried out to check whether the pipeline is missing. Some are based on PID diagrams, while others are based on single line diagrams. I tend to rely on PID diagrams, as there are too many single line diagrams, making it difficult to carry. After confirming that there are no issues, proceed to the next step of pressure testing or air tightness testing.

Pressure tests are generally water pressure tests, and air pressure tests are rare. However, safety measures must be taken, as air pressure tests are too dangerous. If a safety accident occurs, it will be too serious. The test pressure for pressure testing is generally 1.5 times the design pressure. Here, it should be noted that the pressure of the hydrostatic test is definitely greater than the design pressure, and the size of the design pressure is definitely greater than the maximum working pressure of the pipeline. The maximum working pressure is also greater than the working pressure of the pipeline under normal circumstances, all of which are based on safety considerations. Therefore, in general, the safety of the pipeline is guaranteed. The airtightness test is usually conducted through a gas pipeline, using soapy water to coat the weld or flange connection to see if there are any bubbles. The gas is usually air or nitrogen.

There is no problem with the pressure test, usually blowing and insulation can be carried out simultaneously. The blowing must be clean and the pressure must be high, otherwise it is easy to cause corrosion of the inner wall of the pipeline. Take a whiteboard at the compressed air outlet and see that the color of the blown gas on the whiteboard remains unchanged, basically indicating that it has been blown clean. Whether to keep warm or cool depends on the working conditions of the project location and the requirements of the medium. This is the scope of responsibility for design.

After the insulation and cooling are completed, the blowing is finished, and the pipeline is reset, the trial operation can be carried out. At the same time, the construction of factory identification colors can also be carried out. The identification color of each industry is different, and construction can be carried out according to the requirements of each industry and project. After the trial run is completed, the data can generally be organized and handed over.

The construction process of industrial pipelines is not difficult, mainly the quality control in the middle, and the key points of quality control in each process must be grasped well. In addition, as a manager, material management, labor management, schedule management, business affairs, and civilized construction on site are also abilities that a manager should possess.
Weifang Fulai Boiler Energy saving Equipment Technology Co., Ltd. has qualifications such as "D1D2 Pressure Vessel Manufacturing License", "GB2 (2)", "GC2 Pressure Pipeline Installation, Renovation and Maintenance License", and "Level 3 Boiler Installation, Renovation and Maintenance License". contact number: