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The process of addressing the explosion risks associated with small-diameter pressure pipelines involves several key steps and countermeasures. First, it's essential to enhance the training and technical skills of the personnel involved. This includes analyzing past incidents to identify the root causes of failures in small-diameter pipes and pressure vessels, which helps prevent similar issues from recurring.
Second, increasing the sense of responsibility among employees is crucial. Ensuring that all maintenance work meets high-quality standards and follows strict technical specifications can significantly reduce the risk of accidents. Every detail must be carefully addressed during the overhaul process to avoid oversight.
Third, improvements should be made to the steam and water system maintenance. This includes installing expansion joints, fixed casing clamps, and ensuring proper pipeline layout and slope according to design requirements. These measures help manage thermal expansion and reduce stress on the system.
Fourth, valves should be opened and closed slowly to maintain stable water flow and prevent sudden pressure changes that could lead to pipe failure.
Fifth, improving the quality of the water supply is another important step. Clean and properly treated water reduces the risk of corrosion and scaling within the pipes, which can weaken their structure over time.
Sixth, continuous monitoring of operating conditions and strict adherence to established procedures are necessary to ensure safe and reliable performance. Any deviations from standard practices should be promptly corrected.
Seventh, the maintenance process itself should be upgraded. For example, using the cold bending method for elbows ensures that the ellipticity does not exceed 12% of the pipe diameter. A larger bending radius should be used to minimize internal medium corrosion, but it should not exceed four times the nominal diameter. Mechanical cutting methods are recommended for welding joints, and isolation devices should be installed to prevent vibration and movement in the pipeline system.
Eighth, any pipelines that do not meet regulatory standards should be replaced without delay. In unstable sections, fixed splints and anti-wear sleeves should be added to provide additional support and protection.
Ninth, the temperature-reducing jellyfish tube should be replaced from the root of the water supply pipe outlet to the temperature-reducing water platform tee. The elbow should be processed using mechanical cold bending, and supports and hangers should be arranged as per regulations. Expansion bends (G type or F type) should be installed, and all welds should be completed using sub-arc bottoming and electric cover welding techniques.
Tenth, when maintaining the water supply pipeline, replace the discharge pipe elbow and straight sections, regular sewage pipe elbows, and bottom heating pipe elbows. All elbows should be bent using a pipe bender, and all pipe cuts should be made with a saw. After welding, heat treatment should be applied at a controlled temperature between 720°C and 750°C.
Eleventh, when repairing or replacing parts of the superheater drain pipe, use materials such as 12CrMoV for all components. Elbows should be formed using a pipe bender, and all pipe cuts should be done with a saw (electric or manual). All welds should undergo heat treatment at the same temperature range as above.
Twelfth, all small-diameter pressure pipes and elbows should be inspected during furnace shutdowns. Metal testing personnel should conduct non-destructive testing, measure hardness, wall thickness, and ellipticity (for alloy pipes, wall thickness should not exceed 25 mm; for carbon steel pipes, it should not exceed 30 mm; ellipticity should not exceed 12% of the pipe diameter). Visual inspections and sample cutting tests should also be performed to ensure the integrity of the piping system.
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