How to determine whether the installation of compressed air pipelines is qualified?

As an important component of industrial production, the design, installation, and maintenance of compressed air pipelines have a significant impact on the efficiency, energy consumption, and safety of the system. By rational layout, selection of suitable materials and pipe diameters, control of pressure loss, regular maintenance, and adoption of energy-saving measures, the operational efficiency of compressed air systems can be effectively improved, energy consumption can be reduced, and equipment life can be extended. In the future, with the application of intelligence, green environmental protection, and new materials, compressed air pipeline systems will usher in a broader development prospect.

In industrial production, compressed air is widely used in pneumatic equipment, spraying equipment, packaging equipment, etc. For example, in automobile manufacturing, compressed air is used to drive robotic arms and spray paint the body of the car; In food processing, compressed air is used to clean equipment and package products. In the medical field, compressed air is used to drive equipment such as ventilators and surgical instruments, ensuring the accuracy and safety of medical operations.

How to determine whether the installation of compressed air pipelines is qualified?

VISUAL INSPECTION

Pipeline layout: Check whether the pipeline layout meets the design requirements, has a reasonable direction, is easy to operate and maintain, and does not hinder the operation of other equipment and personnel access. The arrangement of pipelines should be neat and beautiful, and pipelines in the same area should be kept parallel or perpendicular as much as possible.

Connecting components: Check whether the connections between pipes, pipes and fittings, and pipes and equipment are firm, whether the welds are uniform, full, and free of defects such as pores, slag inclusions, and cracks. The bolts for flange connection should be complete and tightened, the nuts should be on the same side, and the exposed thread length should be consistent. The card sleeve connection, threaded connection and other parts should be free of looseness and leakage.

Support and fixation: Check whether the supports and hangers of the pipeline are installed firmly and whether the spacing meets the requirements. The form and specifications of brackets and hangers should match the diameter and weight of the pipeline, and there should be no deformation, damage, or looseness. The pipeline should be securely fixed on brackets and hangers without any shaking or displacement.

Identification: Check whether there are clear markings on the pipeline, indicating the name, flow direction, and other information of the medium inside the pipeline. The identification should be prominent, durable, and located for easy observation.

Sealing inspection

Pressure test: Conduct an air tightness test, with a test pressure usually 1.15 times the working pressure, but not less than 0.6 MPa. Fill the pipeline system with compressed air, reach the test pressure, and maintain it for a period of time (generally not less than 30 minutes) to observe whether the pressure drop is within the allowable range. If there is no significant pressure drop (usually not exceeding 1% of the test pressure per hour), it is considered to have good sealing performance.

Soap water detection: Apply soap water to the connections, valves, flanges, and other parts of the pipeline to observe for the formation of bubbles. If bubbles appear, it indicates that there is a leak in that area and repair is needed.

Helium mass spectrometer leak detection: For some occasions with high sealing requirements, helium mass spectrometer leak detector can be used for detection. Fill the pipeline system with helium gas, and then use a helium mass spectrometer leak detector to detect the surface of the pipeline. If there is a leak, the leak detector will detect the helium gas signal to determine the location of the leak.

Pipeline slope inspection

Use a level or slope gauge to check the slope of the pipeline. The pipeline should have a slope of not less than 0.002-0.005, and the slope direction should meet the design requirements. It is 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. Exhaust valves and drain valves should be installed at the highest and lowest points of the pipeline respectively to ensure the smooth discharge of gas and condensed water inside the pipeline.

Pressure loss inspection

During the operation of the pipeline system, use a pressure gauge to measure the pressure at different locations and calculate the pressure loss. The pressure loss should be within the allowable range of the design. Generally speaking, for long-distance compressed air pipelines, the pressure loss per 100 meters should not exceed 0.05-0.1MPa. If the pressure loss is too large, it may be caused by the inner diameter of the pipeline being too small, too many bends, pipeline blockage, or incomplete valve opening, and further inspection and rectification are needed.

Flow check

Use a flow meter to measure the flow rate of compressed air and check if the actual flow rate can meet the requirements of the gas equipment. If the flow rate is insufficient, it may be caused by excessive pipeline resistance, insufficient gas supply, or problems with gas equipment, and corresponding investigation and treatment are needed.

Equipment operation inspection

Check whether the equipment such as filters, dryers, valves, etc. are installed correctly and running normally. The pressure difference between the inlet and outlet of the filter should be within the specified range, the drying effect of the dryer should meet the requirements, and the opening and closing of the valve should be flexible without jamming or leakage. At the same time, check whether the gas equipment is working properly when using compressed air and whether there are any malfunctions caused by compressed air quality or pressure issues.

Compressed air pipelines are an indispensable and important component in industrial production, widely used in various fields such as manufacturing, chemical industry, food processing, and medicine. Its main function is to deliver the compressed air generated by the compressor to various usage points, ensuring the normal operation of the equipment. The design, installation, and maintenance of compressed air pipelines directly affect the efficiency, energy consumption, and safety of the system.

The selection of pipe diameter directly affects the conveying efficiency and pressure loss of compressed air. A diameter that is too small can lead to excessive pressure loss, affecting the effectiveness of the terminal equipment; Excessive pipe diameter will increase costs and installation difficulties. The appropriate pipe diameter is usually calculated based on the flow rate, pressure, and pipeline length of compressed air.