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The pipe spool fabrication line has unique structure, high degree of automation, convenient operation, stable and reliable continuous production. The pipes produced by this pipe spool fabrication line have moderate rigidity, strength, good flexibility, creep resistance, environmental stress cracking resistance and good thermal welding performance, and have become the first choice for urban gas pipelines and outdoor water supply pipes. However, there are still some problems when using the pipe spool fabrication line.

 

Here is the content list:

l Failure of the production line and corresponding measures.

l Computer system failure and corresponding measures.

l Pipe spool fabrication line failure and corresponding measures.

 

Failure of the production line and corresponding measures.

l The outer surface of the pipe spool fabrication line is rough

①　Adjust the pipe spool fabrication line of process temperature: reduce the cooling water temperature, the best cooling water temperature of the PE pipe is 20~25℃

②　Check whether the waterway is blocked or the water pressure is insufficient;

③　Check whether the heating ring of the barrel, head, etc. is damaged;

④　Adjust the water flow of the sizing sleeve;

⑤　Please consult the raw material supplier for the raw material parameters of the batch;

⑥　Check the mold core temperature, if it is higher than the die temperature, reduce the mold core temperature;

⑦　Clean the mold;

 

l Grooves appear on the outer surface of the plastic pipe

①　Adjust the water outlet pressure of the sizing sleeve, and balance the water output;

②　Adjust the nozzle angle in the vacuum forming box to evenly cool the pipeline;

③　Check the mold, sizing sleeve, cutting machine and other hardware for debris and burrs;

 

l There is a jitter ring inside the pipe spool fabrication line

①　Adjust the water outlet of the sizing sleeve to make it even.

②　Adjust the vacuum degree of the second chamber so that the vacuum degree of the rear chamber is slightly higher than that of the front chamber;

③　Check whether the vacuum seal is too tight;

④　Check whether the tractor is shaking;

⑤　Check whether the host output is even;

 

l The outer diameter of the pipe spool fabrication line is out of tolerance

①　Adjust the vacuum to change the size of the outer circle;

②　Adjust the traction speed to change the outer ring size;

③　Correct the size of the inner hole of the sizing sleeve;

 

l Uneven wall thickness of pipe spool fabrication line

①　Adjust the wall thickness of the mold; adjust the nozzle angle in the vacuum setting machine and spray box to uniformly cool the pipeline.

②　Adjust the water outlet of the sizing sleeve to make it even.

③　Disassemble the mold, check whether the screws in the mold are loose, and then tighten it again;

 

Computer system failure and corresponding measures.

Computer system failure

When the computer is turned on or running, pipe spool fabrication line is not allowed to enter the test state.

 

Pipe spool fabrication line failure and corresponding measures.

l Problem 1: The tensile strength and toughness are poor. The tensile strength curve of pipe spool fabrication line should have obvious yield strength and greater elongation, while poor plastic pipes are usually fragile, low elongation and easy to break.

l Problem 2: Poor impact resistance. According to the GB/T5836.1-92 standard, the drop hammer impact test was tested. After years of testing, it was found that the pass rate was only less than 50%, and many pipe spool fabrication line were even damaged by 10 times.

l Problem 3: The softening temperature is low and it is easy to deform after being heated. It is shown in the test performance, that is, the Vicat softening temperature is relatively low (less than 79). Some manufacturers only increase the amount of filler during the compounding process to increase the softening temperature.

 

This can indeed increase the softening temperature, but will greatly reduce the other properties of the pipe, especially impact resistance, tensile strength and toughness. Therefore, in order to increase the softening temperature without reducing or seldom reducing other properties, attention must be paid to the selection of additives, the ratio of raw materials, the production process and the production machinery, Can not be taken lightly.

 

Pipe spool fabrication line is tested in accordance with the national standard GB/T10002.1-1996, and its hydraulic inspection performance standard value requirements are relatively high, which puts forward high requirements for enterprises that produce pipe spool fabrication line. The eccentricity problem is one of the common plastic pipe problems, which will result in large uneven wall thickness of the produced plastic pipes, which not only causes waste of raw materials, but also makes it difficult for the water pressure test performance to meet the requirements.

 

The operation of the pipe spool fabrication line has a great impact. Therefore, this requires manufacturers not only to match the materials well, but also to install online testing equipment so that qualified companies can adjust the size deviation of the plastic pipe at any time.

Before using the fuel tank hydraulic jacking system, you should fully check whether the metal structural components and appearance are intact, whether the sound is normal when running at no load, whether the brake is reliable for heavy load testing, whether the safety limits and protection devices are intact, and the most indispensable Is the safety device reliable?

 

Here is the content list:

l What are the operational safety requirements for tank hydraulic jacking system?

l What is the safety device of the tank hydraulic jacking system?

l Specific operating rules for tank hydraulic jacking system.

 

What are the operational safety requirements for tank hydraulic jacking system?

1. Tank hydraulic jacking system drivers and signal personnel must be specially trained

2. Pay attention to whether the tower type learned by the tank hydraulic jacking system driver is consistent with the actual tower type

3. Implement a dedicated person and plane to manage tank hydraulic jacking system, captain responsibility system, and strict handover system

4. The newly installed tank hydraulic jacking system or the tank hydraulic jacking system after overhaul must be commissioned according to the instructions.

5. Keep a safe distance between tank hydraulic jacking system and overhead transmission lines

6. Applicable fire extinguishing equipment should be equipped in the driver's cabin of tank hydraulic jacking system

 

What is the safety device of the tank hydraulic jacking system?

The installation of tank hydraulic jacking system shall not use aluminum conductor and screw steel as grounding body or underground grounding wire. The wires connected by bolts must have one end. There are three main ways to ground:

①　The grounding body adopts regular grounding piles, or 33*4.5 long 1.5m steel pipe, or 70*70 long 1.5m angle steel.

②　The grounding plate is made of steel plate or other ductile metal plate, with an area of 1 square meter and a depth of 1.5m from the ground.

③　Copper conductors with a cross-section of not less than 28 mm or steel conductors with a cross-section of not less than 50 mm are buried in the wire slot, and the buried length is determined by the grounding resistance.

 

In the above three methods, the cross-sectional area of the copper wire drawn from the grounding body should not be less than 25. If the soil is poorly conductive, sodium chloride (table salt) can be buried in the soil. Then fill it with water. For the tank hydraulic jacking system, each rail must be grounded, the two rails should be connected by a wire, and the two rails should also be electrically connected.

 

l About tank hydraulic jacking system safety device:

1. A safety device that prevents the sling on the hook from slipping off automatically.

2. Install a compression spring sheet at the opening of the hook head to close the opening. This spring sheet can only be pressed down and cannot be turned up after the sling is put in. It can prevent the sling of the tank hydraulic jacking system from falling off automatically.

3. Drum safety device: An effective measure to prevent accidents caused by improper winding of the steel wire rope beyond the drum.

4. A steel bar is welded outside the drum to restrict the wire rope to only move within the drum.

5. Fixed foundation: The digging trench is 600mm deep, concrete is poured on the lime soil, the surface is smooth, and there are waterproof and grounding protection measures.

 

Specific operating rules for tank hydraulic jacking system.

Before use, check that the metal structural parts and appearance are in good condition, the sound is normal when running under no load, the brake is reliable in the heavy load test, the safety limit and protection devices are complete, and the action is sensitive and reliable before operation.

 

When operating each controller, it should be operated step by step, and it is strictly forbidden to operate over gear. When changing the direction of rotation, the operating handle should be reset to zero, and the motor should stop rotating before reversing the operation. Strive for stability, and it is strictly forbidden to start and stop.

 

During the operation of the tank hydraulic jacking system, if any abnormality of the machinery is found, it should be shut down immediately for inspection, and operation can only be carried out after the fault is eliminated.

 

It is strictly forbidden to work with a certificate, and it is strictly forbidden to work after drinking. It is strictly forbidden to use the travel switch to replace the parking operation. It is strictly forbidden to work in violation of regulations, leave the work post or give the machine to others to drive.

 

When loading heavy objects, you should leave the ground at a certain distance and check that the brake is reliable before proceeding.Insist on "ten" not hanging. After the operation is completed, the box should be powered off and the machine should be "crossed"!

This paper will mainly introduce the unfixing holding-latch hydraulic jack, Hydraulic jack is one of the key products of WINCOO ENGINEERING CO.,LTD.

Here is the content list:

• What is the working principle of unfixing holding-latch hydraulic jack?

• What are the characteristics of unfixing holding-latch hydraulic jack?

• What are the possible faults and solutions in use?

What is the working principle of unfixing holding-latch hydraulic jack?

Hydraulic lifting device (package unit) is evenly distributed around tank inner wall. Tank top and upper (the first layer) wall plates are lifted first and then install and weld wall plates of tank body. Self locking hydraulic jack and hydraulic hoist composing of lifting frame and lifting rod are adopted. When oil enters hydraulic jack, upper clamp fastens and lifts lifting rod and expansion ring and mobilize tank (including tank top) to ascend upward. When oil returns to jack, upper clamp returns with piston and lower clamp automatically fastens lifting rod without gliding. The jack repeats the movement and make lifting rod ascend with tank to designated height (spare height for next layer of plate). After butt weld of next layer of wall plates, open upper and lower loosening device and loosen upper and lower clamp to make lifting rod and expansion ring descend to lower expanded and welded rib plate of the next layer of wall plates and then lift. Repeat the process and ascend welded tan till the last layer of wall plates are installed and welded. The installation of the whole storage tank is completed.

What are the characteristics of unfixing holding-latch hydraulic jack?

1.Hydraulic lifting is stable, safe and reliable. The system adopts uniform control and single or partial (several) adjustment can be realized, so the lifting process is relatively stable. Characteristics of unfixing jack determine its good self-locking performance, without tank or heavy object gliding or falling due to power outage, which ensures safe and reliable hydraulic lifting.

2.Construction quality is guaranteed. Lifting height can be precisely controlled because of adjustable function (slightly descending). Welding quality if rank is guaranteed for the reasons given above.

3. Equipment is easy for operation with good working environment and efficiency.

4. The equipment has good adaptability. This set of equipment is applicable to hydraulic lifting of large-scale storage tanks with various volumes ranging from tens of thousands of cubic meters only by regulating hydraulic hoist (unfixing jack, hoisting frame, lifting rod, etc.)

5. Hydraulic pump station can be arranged at proper position as per actual working conditions. For large scale storage tanks, hydraulic pump station can be placed inside the tank, outside the tank or space between two tanks (when one pump station controls two tanks installation) for construction control.

6. Hydraulic pump station has manual and automatic controls with apparent features as strong adaptability and good technical performance price ratio.

7.Short construction period, low cost and good economic returns. Due to high modernization of package unit and fast lifting speed, the unit has low construction cost and good economic returns. The techniques has such advantages as easier for centralized control, convenient operation, safety and reliability (no falling), precise control of weld clearance and lifting height, which guarantees project quality, saves labor and reduces cost with remarkable economical benefit.

8.Unfixing jack is widely used in project installation due to its scientific structural design. The jack is composed of upper clamp, oil cylinder, lower clamp and support. Upper and lower clamps are equipped with self locking device. Upper clamp automatically locks lifting rod when oil cylinder ascends and lower clamp automatically loosens. During stroke return, upper clamp loosens and lower clamp locks lifting rod, thus, lifting rod cannot descend and lift heavy object to designated height step by step. The heavier the object is, the tighter the locking device locks. Heavy objects will not fall even during sudden power cut or oil pipe burst. This lifting mode is proven to be safe and efficient with low cost compared with pneumatic jack, big stroke jack and high altitude stranded wire lifting. These modes are not comparable to unfixing jack in terms of safety and practicability and it is the optimal product and installation for substitution. Unfixing jack is rapidly developed and applied in inversed lifting installation of storage tanks, power plant absorption tower and stack steel lining. This jack has slight descending function, which is convenient for plate to plate butt weld. As long as chaining fixing of support and lifting point are sufficient for bearing object load, the jack can lift object to designated place safely and efficiently.

What are the possible faults and solutions in use?

Faults	Possible causes	Solutions
The   jack cannot lift or lifting stroke is inadequate	1.   Lifting rod is partially deformed or inclined	A.   Shake or vibrate lifting rod prior to lifting. B. Replace or adjust lifting   rod straight
	2.   Upper and lower oil path is mistakenly connected	Connect   oil path as specified.
	3.   Upper and lower clamp block teeth are severely worn. Clamp block support is   damaged or spring fatigued or lost	Replace   clamp block, base or spring
	4.   Backspring fractures or severely deforms	Replace   backspring
	5.   Insufficient oil supply pressure	Adjust   working pressure of oil pump
	6.   Heavy load	Take   measures to decrease load or add jack
	7.   Jack piston seal is damaged	Replace   damaged seal ring
Oil   penetration or oil leakage	1.   Seal element is damaged, severely worm or invalid for aging	Replace   corresponding seal element.
	2.   Cylinder galling	Repair   or replace cylinder
	3.   Loose connection or damaged seal element	Fasten   connection thread or replace corresponding seal element
Oil   leakage at quick coupler	Coupler   or O-ring damaged	Replace   coupler or corresponding O-ring
Stepping   up failure	Reversed   rotation of motor	Adjust   motor rotation direction
	Solenoid   valve fails	Check   and replace new solenoid valve
	Low   oil level	Replenish   hydraulic oil till surpassing red scale
	Oil   pump severely damaged or worn	Replace   oil pump

Above, we introduced the principle of hydraulic jack, characteristics and possible problems and solutions. I believe you have a more detailed understanding of the hydraulic jack. When hydraulic jack homework need the cooperation of all parts, any accessories problems may make hydraulic jack cannot normal use, therefore, to know hydraulic jack structures not only help us to understand the principle of it, will also help us in a timely manner when it fails to distinguish and confirm fault promptly eliminate, can let hydraulic jack to provides us with better services.

In order to give full play to the advantages of pipeline prefabrication equipment and overcome the limitations of fixed pipe spool fabrication line, we have developed a movable pipe spool fabrication line, which has been used in PetroChina, Sinopec, and China National Chemical Corporation. So, what are the precautions for the quality inspection of the pipe spool fabrication line?

 

Here is the content list:

l About the quality inspection content of the pipe spool fabrication line.

l The product parameter mark on the pipe spool fabrication line.

l How to inspect the pipe spool fabrication line?

 

About the quality inspection content of the pipe spool fabrication line.

The pipe spool fabrication line consists of a work station for pipe beveling, a work station for pipe mechanical assembly, a work station for automatic pipe welding, a steel structure work station frame that can be quickly disassembled, a trolley railing system and a light rail to form a transportation system.

 

The testing items of the pipe spool fabrication line include: density, melt mass flow rate, hydrostatic pressure, ring stiffness, flatness, ring flexibility, thermal stability, volatile content, moisture content, carbon black content, carbon black dispersion, Pigment dispersion, gas component resistance, rapid crack propagation resistance component analysis, component content detection, etc.

 

The product parameter mark on the pipe spool fabrication line.

The comprehensive performance of pipe spool fabrication line will reach a high level in China:

1. In the detailed design, China's most advanced "Pipe Manufacturing Design System" software is used to realize the rapid drawing of the pipe spool fabrication line. After the IDF interface module is configured, the design data of the PDS and PDMS design institutes can be directly shared, so a "seamless combination" is realized between design and construction.

2. In the manufacturing management, the domestic first-class "pipe manufacturing and installation management system" software is used to realize all-round information management of the entire pipe spool fabrication line manufacturing process.

3. Pipe spool fabrication line groove adopts a reliable pipeline groove mobile workbench, two of which are used for pipe groove.

4. Roller bed type pipe plasma cutting and beveling machines have been used to cut pipes and form bevels in one step through thermal cutting and processing.

5. An efficient pipe cutting band saw machine and a fixed radial pipe end beveling machine are used to cut the pipe and machine the bevel according to the working procedure.

6. The unique mobile workstation for pipe mechanical assembly in China has been used for weld assembly to mechanically assemble pipe shaft welds.

7. Cover pipe welding adopts advanced automatic pipe welding movable workstation, pipe spool fabrication line automatic welding machine is used to realize efficient automatic cover pipe welding of pipe shaft.

8. The logistics transportation adopts the light rail transportation system, the station frame and the trolley railing system. The light rail transportation system is used for long-distance mechanical logistics transportation, and the station frame is used for transportation. The overhead railing system is used for container internal and external logistics transportation.

9. The pipe spool fabrication line project has a production capacity of 3000 inches/year and a day's production capacity of 1000 inches/day, which meets the huge engineering demand for prefabricated pipelines.

How to inspect the pipe spool fabrication line?

Pipe spool fabrication line has now been widely used in all aspects of people's lives, and unqualified pipes directly affect people's quality of life and health. At the beginning of 2014, some media exposed the problem of individual companies using recycled waste to produce drinking water distribution pipes and fittings, which had a bad social impact. So how to enter the site to inspect the pipe spool fabrication line?

 

The material, specification, model and quality of the pipe spool fabrication line and pipe fittings should meet the current national product standards and design requirements.The appearance quality of the pipe spool fabrication line should not only meet the requirements of its product standards, but also the following requirements:

 

l There are no defects on the surface such as cracks, shrinkage holes, slag inclusions, folding, heavy leather, and rust or dents that do not exceed the negative deviation of the wall thickness;

l The thread surface is intact without damage, and the flange sealing surface is flat, smooth, without burrs and radial grooves;

l The gasket has no aging deterioration or delamination phenomenon, and no defects such as wrinkles on the surface.

l Inspection quantity: all inspections. Check the factory inspection report and certificate.

l Inspection method: observe and inspect.

l The size, wall thickness and allowable deviation of the pipe spool fabrication line should meet its product standards and design requirements.

l Inspection Quantity: 20% of the products of each specification and model are randomly checked by the number of pieces, and no less than 1 piece

l Inspection method: measure with steel ruler and vernier caliper.

 

For the pipe spool fabrication line belonging to one of the following conditions, sampling shall be conducted by the supervision engineer, and the inspection and re-inspection shall be carried out by a qualified inspection unit. The re-inspection results shall meet the current national product standards and design requirements.

What is more?  WINCOO provide not only pipeline construction solutions, but also pipe spool fabrication solutions for customers from everywhere!

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