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The specific implementation process for addressing the explosion risk in small-diameter pressure pipelines involves several key countermeasures. First, it's essential to enhance the technical skills of the staff by conducting comprehensive training sessions. This includes analyzing past incidents to identify root causes and improve future practices.
Second, fostering a strong sense of responsibility among employees is crucial. This ensures that maintenance work is carried out with precision and attention to detail, meeting all required specifications and standards.
Third, the steam and water system should be systematically reviewed and upgraded to meet design requirements. This includes installing expansion joints, fixed clamps, and ensuring proper pipeline layout and slope as per regulations.
Fourth, valves should be opened and closed slowly to maintain steady water flow and reduce stress on the system. Fifth, improving the quality of the water supply is also important to prevent corrosion and other issues that could lead to failure.
Sixth, continuous monitoring of operational conditions and strict adherence to standard operating procedures are necessary to ensure safe and reliable performance.
Seventh, the maintenance process should be refined. For example, cold bending techniques can be used for elbows, with ellipticity not exceeding 12% of the pipe diameter. A larger bending radius should be applied to reduce internal corrosion, but not more than four times the nominal diameter. Mechanical cutting should be used for welding joints, and isolation devices should be installed to prevent vibration and shaking.
Eighth, any pipelines that do not meet regulatory standards should be replaced or inspected thoroughly. On unstable sections, fixed splints and anti-wear pipes should be installed to provide additional support.
Ninth, the temperature-reducing jellyfish tube from the water supply outlet to the temperature-reducing platform tee should be replaced. Elbows should be made using mechanical cold bending, and supports and hangers should be arranged according to regulations. Expansion bends (G type or F type) should be installed, and all welds should be done using sub-arc bottoming and electric cover welding methods.
Tenth, the water supply pipeline should be maintained by replacing elbows and straight sections of the discharge pipe, regular sewage elbows, and bottom heating elbows. All elbows should be bent using a pipe bender, and all cuts should be made with a saw. After welding, heat treatment should be performed at temperatures between 720°C and 750°C.
Eleventh, repairs and replacements of superheater drain pipes should be carried out, using materials such as 12CrMoV. Elbows should be formed using a pipe bender, and all cuts should be made with a saw. Heat treatment should be applied to all welds at the same temperature range.
Twelfth, all small-diameter pressure pipes and elbows must undergo inspection during furnace shutdowns. Metal testing personnel should conduct non-destructive tests, measuring hardness, wall thickness, and ellipticity. For alloy pipes, wall thickness should not exceed 25 mm, while carbon steel pipes should not exceed 30 mm. Ellipticity should not exceed 12% of the pipe diameter. Visual inspections and cut samples should also be conducted to ensure safety and compliance.
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