Industrial pipework systems: technology lines from survey to test

An industrial pipework systems is the sum of pipes, bars and fittings from the outside. However, during the course of the operation, the entire trail acts as a single system: it must take over the effects of the medium, temperature, pressure, vibration and movement, while it must remain accessible and verifiable. Therefore, the construction does not begin by cutting the pipe. First, you have to understand exactly what the pipeline is transporting from where to where, in what operating situations, and how to empty, clean, section or repair it.

The medium and the operating condition determines the system

The material, method and fittings of the wire shall be chosen only in the knowledge of the medium supplied. Other requirements are heating or cooling water, compressed air, a process liquid or a cleaning system. In addition to normal operating conditions, the effects of stopping, starting, emptying, cleaning and any change in temperature shall be taken into account.

It is worth recording the connection points and what belongs to the network. The mutilation of a pump, tank or mechanical device does not in itself mean the system boundary: it is necessary to clarify the coupling fittings, the measuring points, the section and the connection to the control. A significant part of the subsequent debates may be avoided if these limits are already visible at the time of the request for tenders.

On-the-spot survey means more than size taking

In existing plants, plans and real conditions may differ. For this purpose, the available track, wall and surface fractures, the possibility of support structures, the mounting space around machinery and the approach to the work area should be checked. It is equally important to identify the systems in place because the construction must not interfere with another line or maintenance route.

The operator's experience is particularly valuable. He can show you where regular vibration occurs, which section is difficult to empty, where frequent access is required, or which time window to transfer. This information may not be visible on the drawing, but it is relevant for the track and assembly order.

Track, slope and thermal expansion

The shortest route isn't always the best track..3 The position in which the line prevents traffic, covers the interface or there is no room for insulation or operation of fittings shall be avoided. The location of high points, points, emptions and depressions shall be determined in conjunction with the system, not retrospectively.

Due to the change in temperature, the length of the line cannot be ignored. The arrangement of fixed points, directions and sections of movement shall be coordinated with the supports, the structure of the building and the permissible load of the equipment mutilation. The aim is to control the flow of the tube and not report on the weakest connection or support.

Parts and accessories

The tube rack is not a simple suspension. It shall bear the mass of the tube, medium, insulation and fittings while allowing the intended movement. When dividing the holders, attention shall be paid to elbows, branches, heavy fittings and places where the network may receive vibration. It is only useful to connect to existing structures at a point where the suitability is clear.

The location of valves, filters, separators and measuring points is also an operational issue. Be recognizable, operable and interchangeable if necessary. A fitting above head height or covered with cover can be fit on paper, but in practice it is difficult to handle. The layout should therefore also check the direction of treatment and the space required for highlighting.

Workshop preparation and on-site installation

Where the accuracy of the survey and documentation allows, part of the piping sections may be prepared in workshop. This may provide a more orderly manufacturing environment and a more traceable installation, but only if the size of the transport units, the lifting option and the on-site fitting points are appropriate. Too large a prefabricated unit is difficult to get in, and too much on-site fitting may slow the work down.

The choice of welded, floral, threaded or other connections is determined by the need for medium, operating conditions, demolibility and maintenance. The point is not to favour a single type of bond, but to ensure that all connections can be checked, mounted and compatible with the system as a whole.

Work process from survey to test

1. Data definition: the fixing of medium, operating conditions, points of accession, cleaning and system boundaries.
2. Detection and track: checking existing status, collisions, enclosure options, droplets, access and installation routes.
3. Production preparation: compiling materials, drills, fittings, pipe receptacles, prefabricated sections and installation order.
4. Installation: construction of support structures, piping sections, bandages, fittings and fittings.
5. Test and test: visual inspection, binding checks, carrying out a strength or compression test specified for that system.
6. Closure: completion of insulation and marking, monitoring functions, recording discrepancies and documented transfer.

What does a comparable offer have to contain?

When assessing the pipework systems offer, the running meter alone is limited. It should be visible whether the price includes the survey, the piping, the fittings, the breakthroughs, the insulation, the marking, the test and the documentation. It is also important how the offer deals with the transfer to the existing system, the shutdown window and possible reconstructions.

The well-prepared industrial pipework systems not only deliver the medium from one point to the next. It can be separated, controlled, maintained and transmitted in such a way that the operator also knows the actual structure of the system.

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