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Rolling pipe installation is a major project in the installation of hydraulic equipment
Rolled tubeThe quality of installation is one of the keys to the normal performance of the hydraulic system.
1. When designing and piping, all components, hydraulic components, pipe joints, and flanges to be connected should be considered based on the hydraulic schematic diagram.
2. The laying arrangement and direction of pipelines should be uniform and clear-cut. Try to use horizontal or vertical pipe layout. The non-parallelism of horizontal pipes should be ≤2/1000; the non-verticality of vertical pipes should be ≤2/400. Check with a level.
3. There should be a gap of more than 10mm between parallel or intersecting pipe systems.
4. The pipelines should be configured to facilitate the loading, unloading and maintenance of pipelines, hydraulic valves and other components. No matter which section of pipe or component in the system, it should be possible to disassemble and assemble freely without affecting other components.
5. When arranging the length of this hydraulic steel pipe, the pipe must have specific rigidity and vibration resistance. Pipe supports and pipe clamps should be appropriately configured. Bent pipes should be equipped with brackets or pipe clamps near the bending point. Pipes shall not be welded directly to brackets or pipe clamps.
6. The weight of pipelines should not be borne by valves, pumps and other hydraulic components and accessories; nor should the pipelines support the weight of heavier components.
7. For longer pipes, measures must be taken to avoid stress caused by temperature changes causing the pipe to expand and contract.
8. The pipe material used must have a clear original basis. Pipes of unknown materials are not allowed to be used.
9、Rolled tubeDiameters below 50mm can be cut with a grinding wheel cutting machine. Pipes with a diameter of 50mm or more should generally be cut using mechanical processing methods. If gas cutting is used, mechanical processing methods must be used to remove the structural changes caused by gas cutting, and the welding grooves can also be machined. Except for oil return pipes, pressure-controlled pipes are not allowed to be cut with roller-type extrusion cutters. The cutting surface of the pipe should be smooth, and burrs, scale, slag, etc. should be removed. The cut surface should be perpendicular to the axis of the tube.
11. In order to reduce local pressure loss, each section of the pipeline should avoid local sharp expansion or contraction as well as sharp bending of the cross section.
12. If the pipe connected to the pipe joint or flange is a straight pipe, that is, the axis of the pipe should be parallel to and coincident with the axis of the pipe joint and flange. The length of this straight line segment must be greater than or equal to 2 times the pipe diameter.
13. Pipes with an outer diameter less than 30mm can be cold-bent. When the outer diameter of the pipe is 30 to 50 mm, cold bending or hot bending can be used. When the outer diameter of the pipe is greater than 50mm, the hot bending method is generally used.
14. Welders welding hydraulic pipelines should hold a high-pressure pipeline welding certificate.
15. Selection of welding process: Acetylene gas welding is mainly used for general carbon steel pipes with a wall thickness of less than or equal to 2mm. Arc welding is mainly used for carbon steel pipes with wall thickness greater than 2mm. The welding of pipes is best done by argon arc welding. For pipes with a wall thickness greater than 5 mm, argon arc welding should be used for bottoming and arc welding for filling. In certain occasions, the method of filling the pipe hole with protective gas should be used for welding.
Welding rods and flux should be dried according to the product instructions before use, kept dry during use, and used on the same day. The welding rod coating should be free of peeling and obvious cracks.
17. Butt welding should be used for welding long hydraulic steel pipes. Before welding, the surface dirt, oil stains, moisture and rust spots on the groove and its vicinity with a width of 10 to 20 mm should be removed.
18. Butt welding flanges should be used for welding pipes and flanges, and drop-in flanges are not allowed.
19. The welding of pipes and pipe joints should be butt welding, not drop-in type.
20. Butt welding should be used for pipe-to-pipe welding, and drop-in welding is not allowed.
21、Hydraulic pipeWhen butt welding is used, the inner wall of the weld is 0.3~0.5mm higher than the pipe. Recession into the inner wall is not allowed. After welding, use a file or a hand-held grinding wheel to smooth the raised welds in the inner wall. Remove welding slag and burrs to ensure smooth finish.
22. The cross-section of the butt welding seam should be perpendicular to the center line of the pipe.
23. The weld section is not allowed at the corner, and should also be avoided between two elbows of the pipeline.
24. When welding piping, it is necessary to spot weld and position it according to the installation position, then disassemble and weld, and then assemble and trim after welding.
25. During the entire welding process, the welding process should be protected from wind, rain, and snow. After the pipe is welded, the welds with wall thickness less than or equal to 5mm should be cooled naturally at room temperature, and forced cooling by strong wind or water spraying is not allowed.
26. The weld should be fully penetrated and the surface should be even and smooth. The welds of pressure pipelines should be randomly inspected for flaw detection.
27、After the piping is welded, the pipes should be pre-installed according to their location. Connect various hydraulic components, valve blocks, valve frames, and pump stations. Each interface should be naturally aligned and centered, and should not be forced to connect. When loosening pipe joints or flange screws, there must be no large misalignment, seam separation or tilt angle relative to the center line of the joint surface. If this happens, it can be eliminated by fire trimming.
28. The pipe clamps and the frame can be welded firmly after the piping is completed, or they can be interleaved as required.
29. After piping, welding, and pre-installation, disassemble again for pickling and phosphating. After pickling and phosphating, hot air is introduced into the pipe for rapid drying. After drying, if the system is reassembled within a few days and long hydraulic steel pipe oil is passed into the pipe, anti-rust treatment is generally not required, but it should be properly kept. If it needs to be stored for a long time and anti-rust coating needs to be applied, it must be applied after 48 hours of phosphating treatment. It should be noted that the anti-rust coating must be compatible with the cleaning fluid or hydraulic oil used in subsequent pipeline cleaning.
30、Rolled tubeBefore installing again after pickling, phosphating and drying, each rod needs to beRolled tubeThe inner wall is pre-cleaned once. After the pre-cleaning is completed, the system should be reinstalled as soon as possible, and the overall cycle purification of the system should be carried out until the cleanliness level meets the system design requirements.
31. The application of hoses is limited to the following occasions:
Between the movable components of the equipment
Facilitates replacement of replacement parts
Suppresses the transmission of mechanical vibration or noise
32. When installing hoses, care must be taken not to cause additional stress, distortion, sharp bends, friction and other undesirable working conditions to the hoses and joints.
33. Before installing the hose into the system, the inner cavity and joints should also be cleaned.