What are the precautions when installing compressed air pipelines?

As the core part of compressed air transportation, the design, installation, and maintenance of compressed air pipelines directly affect the operational efficiency and service life of the system. By implementing measures such as reasonable layout, selecting suitable pipes, reducing pressure loss, and installing safety devices, the efficient and stable operation of compressed air pipelines can be ensured. With the continuous development of technology, future compressed air pipelines will become more intelligent, energy-efficient, and environmentally friendly, providing more reliable compressed air supply for various industries.

By rational layout and selecting appropriate pipe diameters, pressure drop and energy consumption can be reduced. Using efficient compressors and dryers to reduce system operating costs. Leakage is a common energy waste problem in compressed air systems. By regular inspection and maintenance, timely detection and repair of leakage points can reduce unnecessary energy consumption.

What are the precautions when installing compressed air pipelines?

preparation in advance

Planning and design: Based on the distribution of gas equipment, gas consumption, and working pressure requirements, plan the pipeline layout reasonably, minimize bends and unnecessary fittings as much as possible, in order to reduce pressure loss. At the same time, it is necessary to consider potential expansion needs in the future and reserve a certain amount of interface and pipeline capacity.

Material inspection: Carefully inspect the purchased pipes, fittings, valves, filters, dryers and other materials to ensure that their specifications and models meet the design requirements, the quality is qualified, and there are no defects such as cracks, sand holes, deformation, etc.

Pipe installation

Pipeline cleaning: Before installation, the pipeline must be thoroughly cleaned to remove impurities such as oil stains, rust, and dust inside. Methods such as acid washing and sandblasting can be used to remove rust, and the interior of the pipeline can be wiped or blown clean with a clean cloth or compressed air.

Pipeline connection: Choose the appropriate connection method based on the material of the pipeline. If steel pipes are commonly welded or flanged, the quality of the weld seam should be ensured during welding to avoid defects such as porosity and slag inclusion; Attention should be paid to the selection and installation of gaskets for flange connections to ensure a tight connection. Copper pipes can be connected by brazing or card sleeves, while plastic pipes are generally connected by hot melt or threaded connections. The connection should be carried out according to the corresponding operating procedures to ensure a firm and leak free connection.

Pipeline support and fixation: Pipeline supports or hangers should be installed at regular intervals to support the weight of the pipeline and withstand the pressure of the gas inside the pipeline. The spacing between brackets should be determined based on the diameter, material, and weight of the pipeline. Generally, it should not be too large to avoid excessive deflection or vibration of the pipeline. For longer straight pipelines, expansion joints should also be considered to compensate for the expansion deformation caused by temperature changes in the pipeline.

Pipeline slope: The pipeline should have a certain slope, generally 0.002-0.005, and the slope direction should be determined according to the flow direction of the medium, usually inclined from the air compressor to the direction of the gas equipment, so that the condensed water can naturally flow to the drainage point.

equipment installation

Filter installation: The filter should be installed near the gas equipment to effectively remove impurities from the compressed air. During installation, pay attention to the direction of the inlet and outlet to ensure correct installation, and regularly clean or replace the filter element as required.

Installation of dryer: The installation position of the dryer should consider its working principle and maintenance convenience. For example, refrigerated dryers should be installed in areas with good ventilation and suitable ambient temperature, avoiding installation in high temperature or humid environments; Attention should be paid to the convenience of filling and replacing adsorbents in adsorption dryers, while ensuring that their inlet and outlet pipelines are connected correctly to prevent gas short circuits.

Valve installation: When installing valves, attention should be paid to their type and installation position. Globe valves, ball valves, etc. should be installed in places that are easy to operate and maintain, and attention should be paid to the inlet and outlet directions of the valves to ensure the correct airflow direction. The safety valve should be installed vertically at a higher position in the pipeline, and its outlet should lead to a safe area and not face personnel or equipment.

Security and Testing

Safety measures: During the installation process, construction personnel must strictly follow safety operating procedures and correctly wear protective equipment such as safety helmets and gloves. During welding, cutting and other hot work operations, fire and explosion prevention measures should be taken to ensure the safety of the construction site.

Pressure testing: After installation, the compressed air piping system must undergo a pressure test to check its sealing and strength. The test pressure is generally 1.5 times the working pressure, but not less than 0.6 MPa. During the testing process, it is necessary to carefully inspect the connections of pipelines, fittings, valves, etc. for any leaks. If any leaks are found, they should be repaired in a timely manner and retested until they are qualified.

Purging and Cleaning: After passing the pressure test, the pipeline system is purged and cleaned to remove any impurities that may remain during installation. Compressed air can be used for blowing, and the blowing speed should not be less than 20m/s. The blowing time is determined according to the length of the pipeline and the impurities, generally not less than 15 minutes. After the blowing is completed, the pipeline should be checked for cleanliness and no residual impurities.

The selection of pipes should be determined based on the pressure, temperature, flow rate, and usage environment of the compressed air. Common pipe materials include seamless steel pipes, stainless steel pipes, and pressure resistant plastic pipes. Stainless steel pipes have the advantages of corrosion resistance and high temperature resistance, but the cost is relatively high; Plastic pipes are lightweight and easy to install, but have lower pressure resistance.

Compressor: The core equipment of a compressed air system, responsible for compressing air in the atmosphere to the required pressure. Common types of compressors include piston type, screw type, centrifugal type, etc. Gas storage tank: used to store compressed air, balance system pressure fluctuations, reduce frequent compressor start stop, and extend equipment life. Drying machine: removes moisture from compressed air, prevents freezing and corrosion inside pipelines and equipment, and ensures the dryness of the air.