Pipe spools are the pre-build parts of a piping system. Pipes, flanges, and fittings are called pipe spools and they are produced before they are used in the piping system.

Precautions for pipeline factory prefabrication production

1. Pipeline detail design (secondary deepening design)

On the basis of the construction drawing provided by the design unit, the detailed design (secondary design) of pipeline prefabrication is carried out, and the pipe section drawing suitable for pipeline factory prefabrication and the single line drawing suitable for site installation is generated.

(1) Obtain the pipeline grade list of prefabricated projects from the design department, and establish the pipeline grade database in PDSOFT pipeline factory design system software;

(2) Establish a pipeline model in PDSOFT by using a pipeline grade database and its built-in basic database according to the pipeline horizontal and vertical drawing or original single-line drawing provided by the design department;

(3) According to the actual installation needs and the setting position of accessories, set the site welding position on the pipeline model;

(4) PDSOFT software can be used to automatically generate single-line drawings and pipeline segment drawings. Besides general pipeline information, single line drawing and pipeline segment drawing include:

① Weld number;

② Cutting size of straight pipe section;

(5) Prefabrication technical requirements: construction specifications, pipeline level, heat treatment requirements, primer material, welding method, welding material, film proportion, qualification level, etc.;

(6) Material table.

(7) Input the information of single line drawing and pipe section drawing into the "pipeline Prefabrication Installation Management System"

In order to effectively control the material, quality, schedule and finished product delivery inspection in the process of pipeline prefabrication, the "pipeline prefabrication and Installation Management System" software in the computer-aided prefabrication process management technology was used to input the original information of pipeline single line drawings and pipeline segment drawings.

2. Pipe blanking, pipe fitting groove grinding

(1) Identification transplantation shall be carried out after the completion of the pipe segment feeding. At the same time, identification shall be carried out for each pipe segment with good material feeding according to the feeding table of the single-line diagram. The pipe conveying line in pipeline prefabrication technology is automatically transported to the designated station in the simple assembly welding section.

(2) For pipe sections whose diameter is greater than DN50 and whose length is more than 1 meter, a hollow high-efficiency bevel machine can be used to complete cutting and form a double-sided bevel at one time. According to the actual diameter and wall thickness of the cut pipe, first, adjust the cavity position of the efficient groove machine and the spacing of the cutting groove blade, and then input the length of the cut pipe according to the fixed length system, set the data of the fixed length system, and then operate the efficient groove machine. Clamp the cut pipe and close the isolation door of the rotary head of the efficient beveling machine before cutting. When the cutting is completed, the double-sided groove is also completed;

(3) For the pipe section with a diameter less than DN50 and length less than 1 meter, the pipe shall be transported to the band saw cutting track first, and then the length and Angle shall be adjusted according to the actual situation to make the pipe level with the band saw, and the band saw shall be clamped for cutting. After cutting, a semi-automatic beveling machine is used for beveling processing.

(4) After the cutting, cutting, and groove processing of the pipe section is completed, the inner and outer walls of the pipe mouth shall be polished within 20 mm to remove rust to ensure welding quality;

(5) The groove of the elbow, big and small head, tee, and other pipe fittings shall be polished by a polishing machine and transported to the designated station of the simple assembly welding section by the pipe fitting transport cart.

3. The pipe section has been welded

(1) 60%~80% of the welds suitable for automatic welding in the pipe section are semi-mechanized and bonded by manual argon arc welding, and the cover welding is carried out by using the pipe prefabrication automatic welder in the pipe prefabrication and efficient automatic welding technology;

(2) Semi-finished products of pipe section are automatically transported to designated stations of complex assembly welding section by pipe section conveying line in pipeline prefabrication flow work technology;

(3) Make a daily report of welding joints and input the welding information into the software of "Pipeline Prefabrication and Installation Management System";

(4) For the other welding joints not suitable for automatic welding, manual group matching, manual argon arc welding, and manual welding cover welding;

(5) Pipe section transport vehicle in pipeline prefabrication pipelining technology is used to transport the finished pipe section to be detected through the ground rail to the transillumination room, and the pipe section without flaw detection is transported to the inspection area of the pipe section;

(6) Make daily reports of welds and pipe segments, and input the information of welds and pipe segments into the software of "Pipeline Prefabrication and Installation Management System";

(7) After the pipe segment group is welded, the pipe segment and the weld must be numbered and labeled.

4. Tube section weld inspection

(1) Appearance inspection shall be conducted by the quality inspector according to the construction specifications, including the Angle, size, flatness, and verticality of each pipe segment. According to the design and construction specifications, the corresponding welding joints for radiographic inspection shall be counted and the inspection date shall be issued. At the same time, the order shall be synchronously recorded into the software "pipeline prefabrication Installation Management System";

(2) Inspection personnel shall conduct a radiographic inspection of weld seams in the radiographic inspection room according to the daily commission, wash the film with the automatic film washing machine, and record the evaluation results into the software of "Pipeline Prefabrication and Installation Management System" simultaneously;

(3) The pipe section qualified by flaw detection inspection shall be transported to the inspection area of the pipe section in time.

(4) For the pipe segment with a high requirement of 100% nondestructive testing, the flange and hole tee position can be tested by magnetic particle testing.

5. The tube segment finished acceptance

(1) The integrity and systematicness of the pipe section shall be checked and accepted in the area to be inspected, and then transferred to the purged packaging area of the finished products yard of the pipe section after passing the inspection;

(2) Record of pipe section quality acceptance shall be timely entered into the software of "Pipeline Prefabrication Installation Management System".

6. Pipe segment stored stacked

(1) Air purging shall be carried out inside the pipe section in the purging packaging area of the pipe section finished products yard. After the purging is completed, the two ports shall be sealed, and the outer part of the pipe section shall be painted with the regional color standards;

(2) Pipe sections that have been purged and qualified in packaging shall be hoisted to the designated stacking area and recorded in the acceptance record of pipe sections in time.

7. The finished product gets carried away

(1) Input the pipe section needs a plan of the owner or the site installation unit into the software of "Pipeline Prefabrication Installation Management System", print a list indicating the stack position of the pipe section, and hand it over to the finished product section for pipe section selection and loading;

(2) Make the Record of pipe section Handover synchronously.