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The document provides installation guidelines for laying impulse pipes used in control and instrumentation applications. It discusses general guidelines including limiting pipe lengths to 10 meters, avoiding expansion bends, and maintaining a minimum slope of 1/10 for horizontal piping. It also describes procedures for cleaning pipes using cloth, rods, compressed air and acid solutions. Pipes should be supported at intervals less than 2 meters and proper fittings, cutting, bending and welding techniques should be followed during installation.
The document provides installation guidelines for laying impulse pipes used in control and instrumentation applications. It discusses general guidelines including limiting pipe lengths to 10 meters, avoiding expansion bends, and maintaining a minimum slope of 1/10 for horizontal piping. It also describes procedures for cleaning pipes using cloth, rods, compressed air and acid solutions. Pipes should be supported at intervals less than 2 meters and proper fittings, cutting, bending and welding techniques should be followed during installation.
The document provides installation guidelines for laying impulse pipes used in control and instrumentation applications. It discusses general guidelines including limiting pipe lengths to 10 meters, avoiding expansion bends, and maintaining a minimum slope of 1/10 for horizontal piping. It also describes procedures for cleaning pipes using cloth, rods, compressed air and acid solutions. Pipes should be supported at intervals less than 2 meters and proper fittings, cutting, bending and welding techniques should be followed during installation.
Installation Guidelines for C&I Laying of Impulse Pipe
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General Guidelines on Laying of Impulse Pipe
x The impulse pipe laying is recommended to be limited to a maximum of 10 metres (each limb) generally, unless otherwise specified, to have optimum response from the transmitter. However, this will depend upon plant layout.
x Where the tapping point is subjected to mechanical shift due to heating / cooling of main equipment, care should be taken to route the impulse pipe in such a way as to absorb the shift of tapping point without straining the impulse piping. To accommodate this, sufficient loop for the impulse pipes can be provided near to the tapping point.
x Alternatively hose assembly - S.S. flexible may be used for connection between tapping point and impulse pipe.
x The expansion bends are to be avoided as far as possible, as these act as air / sedimentation traps hampering the system performance.
x Impulse piping shall be arranged as short as possible with a minimum, of bends.
x Horizontal piping shall be provided with 1/10 slope.
x Pipes shall not be laid parallel to high temperature process piping.
x Pipe joints shall be carried out by sockets and flanges. Union fittings may be used when pressure is low. In the case of D.P. instruments both piping on low side and high side shall be maintained at same length and in the same route.
x The impulse pipes used may be of carbon steel or alloy steel or stainless steel for C & I application. The thickness of pipes will vary depending on the schedule of the pipe to proceed with the laying of impulse pipe following procedure shall be followed.
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CLEANING OF IMPULSE PIPE
x The impulse pipes which are stored in the site shall not be used directly, it shall be cleaned first. Initial cleaning of impulse pipe shall be carried out by passing a waste cloth through the pipe and it shall be poked with a metal rod. The procedure shall be repeated two or three times and then compressed air shall be blown.
x Depending on the type of material of impulse pipe, mild acid solution shall be used for cleaning the tube. Hydrochloric acid 4% shall be prepared and tube shall be kept for 30 min. Then the tubes has to be thoroughly cleaned in running water. Finally then shall be cleaned in DM water and dried.
x Once cleaned the tubes shall be erected immediately. If the tubes are not erected immediately the tube ends shall be covered and stored.
LAYING OF IMPULSE PIPE
x The impulse pipe laying is recommended to be limited to a maximum of 10 metres (each limb) from tapping point generally, unless otherwise specified, to have optimum response from the transmitter. However, this will depend upon plant layout.
x Where the tapping point is subjected to mechanical shift due to heating / cooling of main equipment, care should be taken to route the impulse pipe in such a way as to absorb the shift of tapping point without straining the impulse piping. To accommodate this, sufficient loop for the impulse pipes can be provided near to the tapping point.
x Alternatively hose assembly S.S. flexible may be used far connection between tapping point and impulse pipe.
x The expansion bends are to be avoided as far as possible, as these act as air / sedimentation traps hampering the system performance.
x Impulse piping shall be arranged as short as possible with a minimum of bends.
Installation Guidelines for C&I Laying of Impulse Pipe Previous Topic Index Next Topic
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x Horizontal piping shall be provided 1/10 slope positive slope for gas / air service and negative slope for liquid.
x Pipe joints shall be carried out sockets. Union fittings may be used when pressure is low. In the case of D.P. instruments both piping on low side and high side shall be maintained at same length and in the same route.
SUPPORTING OF IMPULSE PIPE
x It should be ensured that the supporting bracket is fixed in such a way that no undue stress is generated in supporting points and piping end, and no leakage is produced. Equal angle shall be used for supporting brackets.
x Impulse piping shall be fixed by U bolts and nuts to the supporting brackets, as shown in the figure.
x Space between supports shall be less than 2 m. key points such as bend, round curve, etc. shall also be supported.
x In the case of parallel impulse piping of more than 2 pipes, the minimum space between pipes shall be arranged such that the space shall be workable on piping wrench and other tools.
x Impulse pipe shall not be supported with platforms, hand rails, vibrating structure etc. Angle brackets shall be welded on to the main structure or to a re-inforcement column or a floor as shown in the figure.
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IMPULSE PIPE FITTING
x Normally socket welded fittings are recommended for impulse pipe. Socket welding does not require edge preparation. However, pipe shall be cleaned and burr should be removed. In view of the above, fast work progress can be achieved.
x S.S. fittings have been recommended for use with alloy steel pipes for two reasons:
x It is difficult to get alloy steel forged fittings or required material, specification from the market whereas S.S. grade forgings are easily available.
x Welding of alloy steel pipe or alloy steel fitting requires use of alloy steel electrodes and welding of such a combination requires preheating and post heating operations and is to be done carefully.
x This is a time consuming process and requires lot of supervision.
x S.S. fitting to alloy steel pipe can be easily welded by arc welding using S.S. electrodes.
x Since cleaning of impulse pipes does not necessitate opening of the pipes from the joints and cleaning is accomplished by a process of blow-back arrangement all fittings have been chosen with welded type.
x Wherever there is absolute necessity, unions have been recommended, thereby restricting the use of the fittings to the bearest minimum.
x The use of fittings may be limited to the minimum unless specifically required for a particular application, for easy maintenance.
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IMPULSE PIPE CUTTING AND BENDING
Cutting
x Pipe cutter or wheel grinder shall be used for pipe cutting.
x Gas cutting shall be avoided.
x Burr inside the cut end shall be removed.
x The cutting surface shall be as perpendicular to the axis as possible.
Bending
x It is recommended for cold bend for the impulse pipes with the help of a hydraulic bender machine to achieve a particular shape.
x Use of 450 elbow and 900 bends (ready-made) is restricted to bare minimum to minimize the number of joints in a system. Hot bending is not be used as this leads to flattening of pipes at the bends and also results in thinning of walls, apart from introducing changes in metallurgical properties of the pipe material.
x Hot bending may be permitted for carbon steel pipe for low pressure service as instructed by supervisor only when it cannot be avoided. In the case of 900 bending the radius shall be more than 3 times the outside diameter of pipe and in the case of U bending, radius of bending shall be 5 times the outside diameter of pipe. When the radius of bending becomes small, elbow fitting shall be used.
x Large bending shall be so made as to form smooth curve.
IMPULSE PIPE WELDING
x Generally, welding of impulse pipe and fitting shall be carried out by arc welding and socket welding is adopted, as shown in the figure. Welding shall be performed by the qualified welders. Only D.C arc welding is recommended for impulse pipe. Motor generator is preferred to rectifier shall be performed on straight portions but not on bent portions.
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x In order to prevent the cracking of the weld it is recommended to provide a small gap between the bottom of the socket and pipe end as shown in the figure.
x Depending on the material type and resource availability different welding methods are followed.
SHIELDED METAL ARC WELDING PROCESS (SMAW)
x The arc is initiated by momentarily touching the electrode to the base metal. The heat of the arc melts the surface of the base metal to form a molten pool at the end of the electrode. The melted electrode metal is transferred across the arc into the molten pool and becomes deposited weld metal.
x It has maximum flexibility and can weld many metals in all positions.
x This process can be used to weld socket type weld.
x Min. thickness of base metal is that can be welded is 1.6 mm for a skilled welder.
GAS TUNGSTEN ARC WELDING PROCESS (GTAW) (TIG)
x The gas tungsten arc welding process utilizes the heat of an arc between a non-consumable tungsten electrodes and the base metal. The arc develops intense heat which melts arc surface of the base metal to form a molten pool. The filler material is externally fed. The filler material is not transferred across the art but melted by it. The arc area is protected from atmosphere by inert shielding gas (normally argon) which flows from the nozzle of the torch. The shielding gas displaces the air so that the oxygen and the nitrogen of the arc does not come in contact with molten metal or the hot tungsten electrode. As the molten metal cools coalescence occurs and parts are joined.
x GTAW is widely used for joining thin wall tubing and for making root passes in pipe points.
x Minimum thickness of base metal that can be welded 0.13mm Installation Guidelines for C&I Laying of Impulse Pipe Previous Topic Index Next Topic
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Advantages x High quality welds in all metals and alloy. x There is no filler material carried across the arc and so no spatter. x Welding can be prepared in all portions. x No slag produced.
GAS METAL ARC WELDING (GMAW)
x The gas metal arc welding process utilizes the heat of an arc between a continually fed consumable electrode and the work to be welded. The heat of the arc melts the surface of this base metal and the end of the electrode. The metal melted off the electrode is transferred through the arc to the work where it becomes the deposited weld metal. The shielding is obtained from an envelope of gas which may be an inert gas. The arc is maintained automatically and travel can be manually or by M/c welding process minor variation in process leads to spray arc welding pulsed arc welding short circuit metal transfer welding etc.
x Min. thickness of metal to be welded should be greater than 0.13 mm.
Advantages x High deposition, rates when related to shielded metal arc welding. x High operator factor with respect to shielded metal arc welding. x High utilization of filler material. x Elimination of slag and flux removal. x Reduction of smoke and fumes.