A processing system for processing an inner wall polishing type process pipeline and a construction method thereof

Abstract

The present application relates to a kind of inner wall polishing type process pipeline processing system and its construction method, belong to process pipeline construction technical field.The process pipeline is composed of straight pipe and pipe fitting, the processing system includes, prefabrication processing tool, for prefabricating the process pipeline;Polishing device is used to polish the process pipeline after prefabrication ends;The polishing device includes polishing motor, the soft shaft fixed in polishing motor output end, the polishing part fixed in the end of soft shaft and the walking component for making the process pipeline and polishing motor relative motion move.By the reciprocating motion of walking component, polishing motor can drive polishing part along the axis of the process pipeline by soft shaft and perform polishing work, the system and construction method can meet the process requirement, and can not be limited by pipe diameter, length and style and other factors.

Description

Technical Field

[0001] This invention belongs to the field of process piping construction technology, specifically relating to a processing system and construction method for an inner-wall polished process piping. Background Technology

[0002] Process piping refers to pipes connected together to meet specific production process requirements. For pipes in pharmaceutical plants, food factories, and other plants with high cleanliness requirements, or pipes used to transport powders with a certain degree of adhesion, the process requirements during pipe construction are also relatively high. Horizontal pipes must be laid with a certain slope, and the inner wall needs to be polished to reduce the friction of materials during transportation in the pipe, ensure smooth material conveying, and prevent pipe blockage.

[0003] Traditional pipeline construction methods involve manual grinding, acid pickling, sandblasting, and shot blasting to process the inner walls of conventional pipes. Manual grinding cannot polish the inner walls of pipes with small diameters. Furthermore, manual grinding is greatly limited by pipe length, the presence of fittings (such as elbows and tees), and weld seams, failing to meet process requirements. In addition, it results in low labor intensity, slow construction progress, and insufficient roughness from acid pickling, sandblasting, and shot blasting. Over long-term use, material adheres to the inner wall of the pipe, increasing frictional resistance and causing the material to accumulate, reducing the pipe's cross-sectional area and decreasing transport efficiency. Ultimately, this can lead to complete blockage, halting production. Therefore, finding a method for constructing pipes requiring inner wall polishing that meets process requirements while being unrestricted by pipe diameter, length, and style has become a significant technical challenge. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a processing system and construction method for an inner wall polishing type process pipeline, which can realize the inner wall polishing after the pipeline is prefabricated, that is, after the pipe fittings and straight pipes are welded, thereby improving efficiency and automation, and overcoming the adverse effects of the above-mentioned traditional construction methods.

[0005] The present invention achieves the above objectives through the following technical solutions:

[0006] A processing system for an internally polished process pipeline, comprising a straight pipe and fittings, the processing system comprising:

[0007] Prefabrication equipment is used to prefabricate the process pipeline, pre-treat the straight pipes and fittings, and connect the straight pipes and fittings.

[0008] A polishing device is used to polish the process pipeline after prefabrication.

[0009] The polishing device includes a polishing motor, a flexible shaft fixed to the output end of the polishing motor, a grinding component fixed to the end of the flexible shaft, and a traveling component for moving the process pipeline relative to the polishing motor. When the traveling component is in operation, the polishing motor can drive the grinding component to perform polishing operations along the axis of the process pipeline via the flexible shaft.

[0010] As a further optimization of the present invention, the polishing device is also used to polish the process pipeline before prefabrication.

[0011] As a further optimization of the present invention, the grinding component is an elastic structure and has an end that abuts against the inner wall of the process pipe, the end of which can spontaneously move radially along the grinding component according to the internal structure of the process pipe.

[0012] As a further optimization of the present invention, the grinding component includes a mounting block fixed to the end of the flexible shaft, and a grinding structure evenly distributed along the circumference of the mounting block, wherein the grinding structure is elastically connected to the mounting block.

[0013] As a further optimization of the present invention, the flexible shaft is further provided with a shaping component, which divides the flexible shaft into a connecting section and a driving section and shapes the flexible shaft. The connecting section is connected to a polishing motor and is used to transmit power to the driving section. Under the action of the shaping component, the driving section applies a pulling force or a pushing force to the polishing component along the axis of the process pipeline.

[0014] As a further optimization of the present invention, the shaping component includes an installation tube fixedly sleeved on the outside of the flexible shaft, a sleeve fixed on the outer periphery of the installation tube, a rod slidably disposed on the inner side of the sleeve, and a positioning block fixed on the end of the rod. The sleeve is provided with a spring that abuts against the rod.

[0015] As a further optimization of the present invention, a first limit switch and a second limit switch are respectively provided on both sides of the walking component, and the walking component includes a support frame for carrying process pipes, as well as casters and a walking motor provided at the bottom of the support frame. The walking motor is connected to the casters through a sprocket and chain transmission mechanism.

[0016] As a further optimization of the present invention, the pipe fitting includes an elbow, a flange, and a gasket.

[0017] As a further optimization of the present invention, the prefabrication processing equipment includes a cutting machine for cutting straight pipes, a pipe beveling machine for beveling straight pipes and elbows, and an electric welding machine for welding the process pipes.

[0018] A method for constructing an internally polished process pipe, based on the aforementioned processing system, includes the following steps:

[0019] S1. Inspection of straight pipes and fittings upon arrival at the site.

[0020] ① Conduct a visual inspection of all raw materials, including straight pipes and fittings. The surface of the raw materials should be free of cracks, scars, pits, inclusions, wrinkles, laps, scratches, and severe rust defects.

[0021] ② All straight pipes and fittings shall be made of 304 stainless steel. The diameter, wall thickness, bending degree and curvature of straight pipes and fittings shall comply with the provisions of the material standard.

[0022] ③ Before use, straight pipes and fittings should be visually inspected to ensure that there are no cracks, slag inclusions, shrinkage cavities, rust or dents exceeding the negative deviation of the wall thickness on the surface.

[0023] ④ The inner diameter of the full-face gasket should be flush with the inner diameter of the weld neck flange;

[0024] S2. Construction Site Preparation

[0025] ① According to the overall construction plan, the raw material storage area, rough polishing area, pipe prefabrication area, fine polishing area and finished product storage area should be arranged in a reasonable manner to avoid unnecessary secondary handling and to connect water, electricity and gas.

[0026] ② Arrange straight pipes and fittings in an orderly manner in the raw material storage area and properly label the materials;

[0027] ③ The bendable polishing device is equipped with two parts, which are installed in the coarse polishing area and the fine polishing area respectively. The polishing device is used to polish the inner wall of raw materials, prefabricated straight pipes and fittings.

[0028] ④ Place prefabrication processing equipment, including cutting machines, pipe beveling machines, and welding machines, in the pipe prefabrication area;

[0029] S3, rough polishing of straight pipes and fittings

[0030] ① The straight pipes and fittings undergo two rough polishing processes. The first polishing process uses a 150# polishing pad, and the second polishing process uses a 240# polishing pad.

[0031] ② Fix the straight pipe or fitting detachably to the traveling component, start the polishing motor and the traveling motor, and slowly move the straight pipe or butt-welded flat flange, large radius elbow fitting towards the polishing motor and perform internal polishing;

[0032] ③ When the walking motor is rotating forward, when the support frame contacts the first limit switch, the walking motor reverses and moves the support frame to the left. When the left side of the support frame contacts the second limit switch, the walking motor rotates forward again. The above working process is repeated. The walking parts go back and forth many times until the rough polishing is completed. Then, the straight pipe and fittings are placed in the prefabrication area for pipe prefabrication and welding.

[0033] S4, Straight pipes, prefabricated pipe fittings

[0034] ① Straight pipes are made of 304 stainless steel seamless steel pipes, elbows are made of 304 stainless steel large radius elbows, flanges are made of 304 stainless steel flat flanges, and gaskets are made of filled polytetrafluoroethylene gaskets.

[0035] ② The process pipeline is used to connect the first storage tank and the second storage tank. The straight pipe is cut into blanks using a cutting machine according to the distance between the first storage tank and the second storage tank.

[0036] ③ When straight pipes are connected to fittings or to another straight pipe, or when they are corner-connected, a pipe beveling machine should be used to bevel the pipe. The beveling type should be V-shaped. The beveling gap should be 1-3mm depending on the wall thickness of the process pipe. It is strictly forbidden to assemble without beveling or gap.

[0037] ④ When welding straight pipes to fittings or straight pipes to another straight pipe, use an electric welding machine for argon arc welding of the root pass and argon arc welding of the cover pass, with internal argon purging for protection.

[0038] ⑤ When welding is completed, a weld is formed. The weld should be marked with information such as pipeline number, weld number, welder number, and welding date.

[0039] ⑥ When connecting straight pipes, the weld position should be controlled within 24 meters. If it exceeds 24 meters, add a pair of 304 stainless steel flat welding flanges to ensure that all inner wall welds of the process pipeline can be polished.

[0040] S5. Non-destructive testing of welds

[0041] ① Welds are divided into butt welds and fillet welds. Butt welds are tested by radiographic non-destructive testing, while fillet welds are tested by dye penetrant non-destructive testing.

[0042] ② Welds that fail non-destructive testing should be repaired immediately and then subjected to non-destructive testing again. Only those that pass the test can proceed to the fine polishing area.

[0043] S6, straight pipes, fittings, and welds are finely polished.

[0044] ① The weld seam is subjected to three rough polishing processes. The first polishing process uses a 60# polishing pad, the second polishing process uses a 150# polishing pad, and the third polishing process uses a 240# polishing pad.

[0045] ② The entire process pipeline is subjected to two rough polishing processes. The grinding structure in the first polishing process uses a 400# polishing pad, the grinding structure in the second polishing process uses an 800# polishing pad, and the grinding structure in the third polishing process uses a 1200# polishing pad.

[0046] ③ Fix the entire process pipeline detachably to the traveling component, start the polishing motor and the traveling motor, and slowly move the process pipeline towards the polishing motor to perform internal polishing;

[0047] ④ When the walking motor is rotating forward, the walking motor reverses when the support frame contacts the first limit switch, causing the support frame to move to the left. When the left side of the support frame contacts the second limit switch, the walking motor rotates forward again. The above working process is repeated. The walking component goes back and forth multiple times until the fine polishing is completed, and then the next polishing accuracy test is carried out.

[0048] ⑤ After fine polishing, the pipe should be sealed immediately to prevent other debris and impurities from entering the pipe.

[0049] S7, Polishing precision inspection

[0050] ① The inner wall polishing of the pipeline is inspected using a TR101 surface roughness tester at the pipeline end, and the roughness is not higher than the design requirements;

[0051] ② Process pipelines whose surface roughness does not meet the design requirements shall not be allowed to enter the installation area;

[0052] ③ For process pipelines that have passed the roughness test, operators must not step on or draw on the polished surface at will;

[0053] ④ For process pipelines that have passed the roughness test, operators are prohibited from hammering, cutting, arc striking, or welding on the polished surface;

[0054] ⑤ The seals on the process pipelines should be reset immediately after inspection;

[0055] S8, Pipeline Installation

[0056] ① Both the first and second storage tanks are installed on the equipment frame. After the frame, the first storage tank, and the second storage tank are installed and aligned, the process pipelines are installed.

[0057] ② Start installing the process piping with the inner wall already polished from the equipment port of the first storage tank. The butt-welded flat flange on the process piping is connected to the flange of the equipment port of the first storage tank with connecting bolts. A full-face gasket is installed between the two flanges. The inner opening of the full-face gasket should be flush with the inner diameter of the flange to prevent material from sticking out.

[0058] ③ During the installation of the process pipeline, a support shall be installed on the process pipeline to avoid stress on the opening of the first storage tank. The pipeline support shall not be welded to the process pipeline whose inner wall has been polished to a qualified standard, but shall be connected by bolts.

[0059] ④ After the process pipeline is connected, install a vibrator to prevent the material from being damp and adhering to the inner wall of the process pipeline. The vibrator shall not be welded to the process pipeline whose inner wall has been polished to a qualified standard; bolts shall be used for connection.

[0060] ⑤ When the process pipeline is installed to the second storage tank, check whether the slope of the process pipeline meets the requirements. Only after the requirements are met can it be connected to the second storage tank.

[0061] S9. Pipeline Acceptance

[0062] ① During the installation of the process piping, the cleanliness of the inside of the process piping should be ensured, and hard tools are strictly prohibited from touching the inside of the process piping;

[0063] ② Check the tightness of the bolts connecting the butt-welded flanges, and use a depth micrometer to check the centering of the full-surface gaskets;

[0064] ③ Check the stability, verticality, and bolt tightness of the support frame;

[0065] ④ Use an angle ruler and a spirit level to measure the horizontality, verticality, and slope of the process pipeline;

[0066] ⑤ Test run the vibrator by powering it on.

[0067] The beneficial effects of this invention are as follows:

[0068] 1) This invention uses a polishing motor and a flexible shaft to drive the grinding component to rotate. The traveling component carries the workpiece to be polished in a reciprocating motion, so that while the flexible shaft rotates the grinding component, it applies a pushing or pulling force to the grinding component. This allows the grinding component to perform automated polishing of process pipes of various shapes. It has good adaptability to pipe length, is simple to operate, and saves manpower.

[0069] 2) The polishing disc of the grinding component of the present invention is connected to the mounting block through an elastic connector and abuts against the inner wall of the pipe. The polishing disc can spontaneously move along the radial direction of the grinding component according to the internal structure of the process pipe, so that the polishing device can adapt to different pipe inner diameters. It can polish pipes with various pipe fittings or welds and pipes with varying diameters, further improving the adaptability to various process pipes.

[0070] 3) The present invention divides the flexible shaft into a connecting section and a driving section by a shaping component, and shapes the flexible shaft. The connecting section is connected to the polishing motor and is used to transmit power to the driving section. Under the action of the shaping component, the driving section applies a pulling or pushing force to the polishing component along the axis of the process pipeline, so as to avoid the polishing component from tilting relative to the cross section of the process pipeline, and further improve the polishing effect.

[0071] 4) In this invention, the prefabrication of process pipelines is carried out with rough polishing and fine polishing respectively. Before prefabrication, polishing discs of different particle sizes are used to perform two polishing processes on straight pipes and fittings. After prefabrication, polishing discs of different particle sizes are used to first perform three rough polishing processes on the weld seam, and then perform two fine polishing processes on the entire process pipeline, thereby further improving the polishing effect of the process pipeline.

[0072] 5) Before the prefabrication and polishing of process pipelines, the present invention rationally arranges a combined area consisting of a raw material storage area, a rough polishing area, a pipeline prefabrication area, a fine polishing area, and a finished product storage area to avoid unnecessary secondary handling and improve the processing efficiency of process pipelines. Attached Figure Description

[0073] Figure 1 This is a site layout diagram of the raw material storage area of ​​this invention;

[0074] Figure 2 This is a site layout diagram of the coarse polishing area of ​​this invention;

[0075] Figure 3 This is a site layout diagram of the pipeline prefabrication area of ​​this invention;

[0076] Figure 4 This is a site layout diagram of the fine polishing area of ​​this invention;

[0077] Figure 5 This is a site layout diagram of the finished product stacking area of ​​this invention;

[0078] Figure 6 This is a partial cross-sectional view of the grinding component of the present invention;

[0079] Figure 7 This is a partial cross-sectional view of the standardized component of the present invention;

[0080] Figure 8 This is an elevation view of the construction method for the process piping of this invention;

[0081] Figure 9 This is a layout diagram of the joint processing site for the process pipelines of this invention;

[0082] Figure 10 This is a flowchart of the construction method for the process pipeline of this invention;

[0083] in, Figure 2 and Figure 4The working status of the polishing device during rough polishing and fine polishing operations are shown respectively. Figure 3 The components of the prefabrication equipment were displayed.

[0084] In the diagram: 1. Prefabrication equipment; 2. Polishing device; 3. Straight pipe; 4. Elbow; 5. Flange; 6. Gasket; 7. Weld; 8. First storage tank; 9. Second storage tank; 10. Frame; 11. Support; 12. Vibrator; 101. Cutting machine; 102. Pipe beveling machine; 103. Welding machine; 201. Polishing motor; 202. Flexible shaft; 203. Grinding components; 204. Traveling components; 205. Shaping components; 206. First row 207. Second limit switch; 2031. Mounting block; 2032. Grinding structure; 2033. Sleeve; 2034. Slide rod; 2041. Support frame; 2042. Caster; 2043. Travel motor; 2051. Mounting tube; 2052. Sleeve; 2053. Rod; 2054. Positioning block; Z1. Raw material stacking area; Z2. Coarse polishing area; Z3. Pipe prefabrication area; Z4. Fine polishing area; Z5. Finished product stacking area. Detailed Implementation

[0085] The present application will now be described in further detail with reference to the accompanying drawings. It should be noted that the following specific embodiments are only used to further illustrate the present application and should not be construed as limiting the scope of protection of the present application. Those skilled in the art can make some non-essential improvements and adjustments to the present application based on the above application content.

[0086] First Embodiment

[0087] like Figure 1-5As shown, this embodiment relates to a processing system for an inner-wall polished process pipeline. The process pipeline consists of a straight pipe 3 and fittings. The processing system includes a prefabrication tool 1 for prefabricating the process pipeline. The prefabrication tool 1 pre-processes the straight pipe 3 and fittings and connects them. The processing system also includes a polishing device 2 for polishing the process pipeline before and after prefabrication. The polishing device 2 includes a polishing motor 201, a flexible shaft 202 fixed to the output end of the polishing motor 201, a grinding component 203 fixed to the end of the flexible shaft 202, and a traveling component 204 for moving the process pipeline relative to the polishing motor 201. When the traveling component 204 is in operation, the polishing motor 201 can drive the grinding component 203 to perform polishing operations along the axis of the process pipeline via the flexible shaft 202. The polishing device 2 uses a polishing motor 201 and a flexible shaft 202 to drive the grinding component 203 to rotate. The traveling component 204 drives the straight pipe, fittings, or prefabricated process pipe to reciprocate. This causes the flexible shaft 202 to rotate the grinding component 203 while applying a pushing or pulling force to the grinding component. This allows the grinding component 203 to perform automated polishing on process pipes of various shapes. It has good adaptability to pipe length, is simple to operate, and saves manpower.

[0088] Specifically, such as Figure 6 As shown, the grinding component 203 includes a mounting block 2031 fixed to the end of the flexible shaft 202, and grinding structures 2032 evenly distributed circumferentially along the mounting block 2031. The grinding structures 2032 are elastically connected to the mounting block 2031 via an elastic connector. This elastic connector consists of a sleeve 2033 fixedly connected to the outside of the mounting block 2031, and a slide rod 2034 fixedly connected to the side of the grinding structure 2032 near the mounting block 2031. The slide rod 2034 is connected to the end of the sleeve 2033 near the mounting block 2031 via a spring. The grinding component 203 is an elastic structure and has an end that abuts against the inner wall of the process pipeline. This end is the end of the grinding structure 2032 away from the mounting block 2031, and can spontaneously move radially along the grinding component 203 according to the internal structure of the process pipeline. The grinding structure 2032 is a fan-shaped polishing disc. The polishing disc is elastically connected to the mounting block 2031 and abuts against the inner wall of the pipe. It can adapt to different pipe inner diameters and can polish pipes with various fittings or welds as well as pipes with varying diameters.

[0089] Please see Figure 1 and Figure 5The pipe fittings include elbows 4, flanges 5, and gaskets 6. Straight pipes 3 are made of 304 stainless steel seamless pipe, and elbows 4 are 304 stainless steel large-radius elbows. The radius of elbow 4 can be a radius R greater than 1000mm, preferably R = 1500mm. Flanges 5 are 304 stainless steel flat flanges. Gaskets 6 are filled polytetrafluoroethylene (PTFE) gaskets, which are full-surface gaskets that prevent leakage of the internal medium of the process pipeline. Welds 7 are formed between the welded straight pipes 3 and other straight pipes 3, and between the straight pipe 3 and elbow 4. The prefabrication equipment 1 includes a cutting machine 101 for cutting straight pipes 3, a pipe beveling machine 102 for beveling straight pipes 3 and elbows 4, and an electric welding machine 103 for welding the process pipeline.

[0090] Furthermore, such as Figure 7 As shown, a shaping component 205 is also provided on the flexible shaft 202. The shaping component 205 divides the flexible shaft 202 into a connecting section and a driving section, and shapes the flexible shaft 202. The connecting section is connected to the polishing motor 201 and is used to transmit power to the driving section. Under the action of the shaping component 205, the driving section applies a pulling or pushing force to the polishing component 203 along the axis of the process pipeline, so as to prevent the polishing component 203 from tilting relative to the cross section of the process pipeline, and further improve the polishing effect.

[0091] Specifically, the shaping component 205 includes a mounting tube 2051 fixedly sleeved on the outside of the flexible shaft 202, a sleeve 2052 fixed on the outer periphery of the mounting tube 2051, a rod 2053 slidably disposed on the inner side of the sleeve 2052, and a positioning block 2054 fixed on the end of the rod 2053. A spring is provided inside the sleeve 2052 to abut against the rod 2053. The rod 2053, in conjunction with the positioning block 2054, provides support for the mounting tube 2051 and the flexible shaft 202 inside the mounting tube 2051, so that the driving section of the flexible shaft 202 is as close as possible to the axis of the process pipeline. This ensures that the direction of the tension or thrust of the flexible shaft 202 on the polishing component 203 is basically consistent with the direction of the axis of the process pipeline, thereby improving the polishing effect.

[0092] In addition, please see Figure 2 and Figure 4The traveling component 204 is equipped with a first limit switch 206 and a second limit switch 207 on both sides. The traveling component 204 includes a support frame 2041 for carrying process pipes, casters 2042 and a traveling motor 2043 located at the bottom of the support frame 2041. The traveling motor 2043 is connected to the casters 2042 via a sprocket and chain drive mechanism. The traveling motor 2043 drives the casters 2042 to rotate, causing the support frame 2041, carrying straight pipes 3, fittings, or prefabricated process pipes, to move between the first limit switch 206 and the second limit switch 207. The two limit switches 207 reciprocate between each other. The traveling component 204 is mounted on a base. The polishing motor 201 is fixed to the base via a mounting bracket. The base is provided with a track corresponding to the caster 2042, and also has multiple switch mounting points. The first limit switch 206 and the second limit switch 207 are detachably installed at the corresponding switch mounting points according to the length of the straight pipe 3, fittings or prefabricated process pipe carried by the support frame 2041, so as to ensure that the distance between the two limit switches is adapted to the length of the workpiece to be polished.

[0093] Second Embodiment

[0094] like Figure 8-10 As shown, this embodiment relates to a construction method for an inner-wall polished process pipe. This construction method is based on the processing system of the first embodiment and includes the following steps:

[0095] S1. Inspection of straight pipes and fittings upon arrival at the site.

[0096] ① Conduct a visual inspection of all raw materials, including straight pipe 3 and pipe fittings. Their surfaces should be free of defects such as cracks, scars, pits, inclusions, wrinkles, laps, scratches, and severe corrosion.

[0097] ② The straight pipe 3, as well as the butt-welded flat flange 5, large radius elbow 4 and other pipe fittings, shall be made of 304 stainless steel. The diameter, wall thickness, curvature and arc of the straight pipe 3 and pipe fittings shall all comply with the provisions of the material standard.

[0098] ③ Before use, straight pipes 3, butt-welded flat flanges 5, large-radius elbows 4 and other pipe fittings should be visually inspected to ensure that there are no defects such as cracks, slag inclusions, shrinkage cavities, rust or dents exceeding the negative deviation of the wall thickness.

[0099] ④ The inner diameter of the full-face gasket 6 should be flush with the inner diameter of the butt-welding flange 5.

[0100] S2. Construction Site Preparation

[0101] ① According to the overall construction plan, the raw material storage area Z1, rough polishing area Z2, pipe prefabrication area Z3, fine polishing area Z4, and finished product storage area Z5 are reasonably arranged together to avoid unnecessary secondary handling. Water, electricity, and gas (steam) are connected. Finished product storage area Z5 is the storage area for polished process pipes.

[0102] ② Arrange the straight pipes 3, butt-welded flat flanges 5, large-radius elbows 4, and other pipe fittings in an orderly manner in the raw material storage area Z1, and properly label the materials.

[0103] ③ Two bendable polishing devices 2 are provided. The two polishing devices 2 are installed in the coarse polishing zone Z2 and the fine polishing zone Z4 respectively. The polishing devices 2 are used to polish the inner wall of raw materials and prefabricated pipes.

[0104] ④ Place the prefabrication processing equipment 1, such as the cutting machine 101, pipe beveling machine 102, and electric welding machine 103, in the pipe prefabrication area 3.

[0105] S3, rough polishing of straight pipes and fittings

[0106] ① Two rough polishing processes are performed on the straight pipe 3 and the pipe fitting. The grinding structure 2032 in the first polishing process uses a 150# polishing pad, and the grinding structure 2032 in the second polishing process uses a 240# polishing pad.

[0107] ② Fix the straight pipe 3 or pipe fittings detachably on the traveling component 204, start the polishing motor 201 and the traveling motor 2043, so that the straight pipe 3 or pipe fittings such as the butt-welded flat flange 5 and the large radius elbow 4 move slowly towards the polishing motor 201 and perform internal polishing.

[0108] ③ The walking motor 2043 rotates forward and drives the caster 2042 to rotate through the sprocket and chain transmission mechanism, causing the support frame 2041 to move to the right. When the right side of the support frame 2041 contacts the first limit switch 206, the walking motor 2043 stops rotating forward. Then the walking motor 2043 reverses, causing the support frame 2041 to move to the left. When the left side of the support frame 2041 contacts the second limit switch 207, the walking motor 2043 stops reversing. Then the walking motor 2043 rotates forward again, causing the support frame 2041 to carry the straight pipe 3 or pipe fittings and move slowly towards the polishing motor 201. The above working process is repeated. The walking component 204 goes back and forth many times until the rough polishing is completed. Then the straight pipe 3 and pipe fittings are placed in the prefabrication area Z3 for pipe prefabrication welding.

[0109] S4, Straight pipes, prefabricated pipe fittings

[0110] ① Straight pipe 3 is made of 304 stainless steel seamless steel pipe, elbow 4 is made of 304 stainless steel large radius (R=1500mm) elbow, flange 5 is made of 304 stainless steel flat flange, and gasket 6 is made of filled polytetrafluoroethylene gasket.

[0111] ② The process pipeline is used to connect the first storage tank 8 and the second storage tank 9. Based on the distance between the first storage tank 8 and the second storage tank 9, the straight pipe 3 is cut and prepared using the cutting machine 101.

[0112] ③ When straight pipe 3 is connected to pipe fittings or to another straight pipe 3, or when they are joined at an angle, pipe beveling machine 102 should be used to open the beveling. The beveling form should be V-shaped. The beveling gap should be 1-3mm depending on the wall thickness of the process pipe. It is strictly forbidden to assemble without beveling or gap.

[0113] ④ When welding straight pipe 3 to pipe fittings or straight pipe 3 to another straight pipe 3, use electric welding machine 103 for argon arc welding for the root pass and argon arc welding for the cover pass, and argon filling for internal protection to reduce weld beads.

[0114] ⑤ When welding is completed, weld seam 7 is formed. Weld seam 7 should be marked, including information such as pipeline number, weld number, welder number, and welding date.

[0115] ⑥ When straight pipe 3 is connected, the position of weld seam 7 should be controlled within 24 meters. If it exceeds 24 meters, add a pair of 304 stainless steel flat welding flanges 5 to ensure that all inner wall weld seams 7 of the process pipeline can be polished.

[0116] S5. Non-destructive testing of welds

[0117] ① Weld 7 is divided into butt welds and fillet welds. Butt welds are tested by radiographic non-destructive testing, and fillet welds are tested by dye penetrant testing.

[0118] ② Welds 7 that fail non-destructive testing should be repaired immediately. After repair, non-destructive testing should be performed again. Only welds that pass the test can proceed to the fine polishing area Z4.

[0119] S6, straight pipes, fittings, and welds are finely polished.

[0120] ① Three rough polishing processes are carried out at the 7 weld seams. The grinding structure 2032 in the first polishing process uses a 60# polishing pad, the grinding structure 2032 in the second polishing process uses a 150# polishing pad, and the grinding structure 2032 in the third polishing process uses a 240# polishing pad.

[0121] ② The entire process pipeline is subjected to two rough polishing processes. The grinding structure 2032 in the first polishing process uses a 400# polishing pad, the grinding structure 2032 in the second polishing process uses an 800# polishing pad, and the grinding structure 2032 in the third polishing process uses a 1200# polishing pad.

[0122] ③ Fix the entire process pipeline detachably to the traveling component 204, start the polishing motor 201 and the traveling motor 2043, and slowly move the process pipeline toward the polishing motor 201 to perform internal polishing.

[0123] ④ The travel motor 2043 rotates forward and drives the caster 2042 to rotate through the sprocket and chain transmission mechanism, causing the support frame 2041 to move to the right. When the right side of the support frame 2041 contacts the first limit switch 206, the travel motor 2043 stops rotating forward. Then the travel motor 2043 reverses, causing the support frame 2041 to move to the left. When the left side of the support frame 2041 contacts the second limit switch 207, the travel motor 2043 stops reversing. Then the travel motor 2043 rotates forward again, causing the support frame 2041 to carry the process pipe and slowly move towards the polishing motor 201. The above working process is repeated, and the travel component 204 moves back and forth multiple times until the fine polishing is completed, and then the next polishing accuracy test is carried out.

[0124] ⑤ After fine polishing, the pipe should be sealed immediately to prevent other debris and impurities from entering the pipe.

[0125] S7, Polishing precision inspection

[0126] ① The inner wall polishing of the pipeline is inspected using a TR101 surface roughness tester at the pipeline end. The roughness is not higher than the design requirements.

[0127] ② Process pipelines whose surface roughness does not meet the design requirements shall not be allowed to enter the installation area.

[0128] ③ For process pipelines that have passed the roughness test, operators must not step on or draw on the polished surface.

[0129] ④ For process pipelines that have passed the roughness test, operators must not perform hammering, cutting, arc striking, welding, or other operations on the polished surface. In special circumstances, it is necessary to consult with the polishing team and carry out secondary polishing.

[0130] ⑤ The seals on the process pipelines after inspection should be reset immediately.

[0131] S8, Pipeline Installation

[0132] ① The first storage tank 8 and the second storage tank 9 are both installed on the equipment frame 10. After the frame 10, the first storage tank 8 and the second storage tank 9 are installed and aligned, the process pipelines are installed.

[0133] ② Start installing the process piping with the inner wall already polished from the equipment port of the first storage tank 8. The butt-welded flat flange 5 on the process piping is connected to the flange 5 at the equipment port of the first storage tank 8 with connecting bolts. A full-face gasket 6 is installed between the two flanges 5. The inner opening of the full-face gasket 6 should be flush with the inner diameter of the flange 5 to prevent material from sticking out.

[0134] ③ During the installation of process piping, install brackets 11 on the process piping to avoid stress on the equipment port of the first storage tank 8. Pipe support 11 shall not be welded to the process piping whose inner wall has been polished to a qualified standard. Instead, bolts shall be used to connect them to avoid overheating and deformation of the inner wall of the process piping.

[0135] ④ After the process piping is connected, install the vibrator 12 to prevent the material from being damp and adhering to the inner wall of the process piping. The vibrator 12 and the process piping with the inner wall already polished should not be welded. Instead, bolts should be used for connection to facilitate disassembly and maintenance in the later stage and to avoid overheating and deformation of the inner wall of the process piping.

[0136] ⑤ When the process pipeline is installed to the second storage tank 9, check whether the slope of the process pipeline meets the requirements. Only after the requirements are met can it be connected to the second storage tank 9.

[0137] S9. Pipeline Acceptance

[0138] ① During the installation of process piping, the cleanliness of the inside of the process piping must be ensured, and hard tools are strictly prohibited from touching the inside of the process piping.

[0139] ② Check the tightness of the connecting bolts of the butt-welded flange 5, and use a depth micrometer to check the centering of the full-surface gasket 6.

[0140] ③ Check the stability, verticality, and bolt tightness of bracket 11.

[0141] ④ Use an angle ruler and a spirit level to measure the horizontality, verticality, and slope of the process pipeline.

[0142] ⑤ Power on and test run the vibrator 12.

[0143] The embodiments described above are merely examples of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. A processing system for an inner-wall polished process pipe, the process pipe consisting of a straight pipe (3) and fittings, characterized in that, The processing system includes: Prefabrication processing equipment (1) is used to prefabricate the process pipeline, pre-treat the straight pipe (3) and fittings, and connect the straight pipe (3) and fittings; Polishing device (2) is used to polish the process pipeline after prefabrication; The polishing device (2) includes a polishing motor (201), a flexible shaft (202) fixed to the output end of the polishing motor (201), a grinding component (203) fixed to the end of the flexible shaft (202), and a traveling component (204) for moving the process pipeline relative to the polishing motor (201). When the traveling component (204) is in operation, the polishing motor (201) can drive the grinding component (203) to perform polishing operations along the axis of the process pipeline through the flexible shaft (202). The polishing device (2) is also used to polish the process pipeline before prefabrication; The grinding component (203) is an elastic structure and has an end that abuts against the inner wall of the process pipe. This end can spontaneously move radially along the grinding component (203) according to the internal structure of the process pipe. The grinding component (203) includes a mounting block (2031) fixed to the end of the flexible shaft (202) and a grinding structure (2032) evenly distributed around the mounting block (2031), wherein the grinding structure (2032) is elastically connected to the mounting block (2031). The flexible shaft (202) is also provided with a shaping component (205). The shaping component (205) divides the flexible shaft (202) into a connecting section and a driving section, and shapes the flexible shaft (202). The connecting section is connected to the polishing motor (201) and is used to transmit power to the driving section. Under the action of the shaping component (205), the driving section applies a pulling force or a pushing force to the polishing component (203) along the axis of the process pipeline. The shaping component (205) includes a mounting tube (2051) fixedly sleeved on the outside of the flexible shaft (202), a sleeve (2052) fixed on the outer periphery of the mounting tube (2051), a rod (2053) slidably disposed on the inner side of the sleeve (2052), and a positioning block (2054) fixed on the end of the rod (2053). The sleeve (2052) is provided with a spring that abuts against the rod (2053). The walking component (204) is provided with a first limit switch (206) and a second limit switch (207) on both sides respectively. The walking component (204) includes a support frame (2041) for carrying process pipes, and a caster (2042) and a walking motor (2043) provided at the bottom of the support frame (2041). The walking motor (2043) is connected to the caster (2042) through a sprocket and chain transmission mechanism. The pipe fittings include elbows (4), flanges (5), and gaskets (6).

2. The processing system according to claim 1, characterized in that: The prefabrication equipment (1) includes a cutting machine (101) for cutting straight pipes (3), a pipe beveling machine (102) for beveling straight pipes (3) and elbows (4), and an electric welding machine (103) for welding the process pipes.

3. A construction method for an internally polished process pipe, characterized in that, The processing system according to claim 2 includes the following steps: S1. Inspection of straight pipes and fittings upon arrival at the site. ① Conduct a visual inspection of all raw materials, including straight pipes (3) and fittings, ensuring that the surface of the raw materials is free from cracks, scars, pits, inclusions, wrinkles, laps, scratches, and severe rust defects. ② The straight pipe (3) and fittings are all made of 304 stainless steel. The diameter, wall thickness, curvature and arc of the straight pipe (3) and fittings shall comply with the provisions of the material standard. ③ Before use, straight pipes (3) and fittings should be visually inspected again to ensure that there are no cracks, slag inclusions, shrinkage cavities, rust or dents exceeding the negative deviation of the wall thickness on the surface. ④ The inner diameter of the gasket (6) is flush with the inner diameter of the butt-welding flange (5). The gasket (6) is made of filled polytetrafluoroethylene gasket, which is a full-surface gasket. S2. Construction Site Preparation ① According to the overall construction plan, the raw material storage area (Z1), rough polishing area (Z2), pipe prefabrication area (Z3), fine polishing area (Z4), and finished product storage area (Z5) should be arranged in a reasonable manner to avoid unnecessary secondary handling and to connect water, electricity and gas. ② Place the straight pipes (3) and fittings in the raw material storage area (Z1) in an orderly manner and label the materials. ③ The bendable polishing device (2) is provided in two parts. The two polishing devices (2) are installed in the coarse polishing area (Z2) and the fine polishing area (Z4) respectively. The polishing device (2) is used to polish the inner wall of the raw materials, the prefabricated straight pipe (3) and the pipe fittings. ④ Place the prefabrication processing equipment (1), including the cutting machine (101), pipe beveling machine (102), and electric welding machine (103), in the pipe prefabrication area (Z3). S3, rough polishing of straight pipes and fittings ① The straight pipe (3) and the fittings are subjected to two rough polishing processes. The grinding structure (2032) in the first polishing process uses a 150# polishing pad, and the grinding structure (2032) in the second polishing process uses a 240# polishing pad. ② Fix the straight pipe (3) or pipe fitting detachably on the walking component (204), start the polishing motor (201) and the walking motor (2043) to make the straight pipe (3) or butt welded flat flange (5) and large radius elbow (4) pipe fitting slowly move towards the polishing motor (201) and perform internal polishing; ③ When the walking motor (2043) is rotating forward, when the support frame (2041) contacts the first limit switch (206), the walking motor (2043) reverses, causing the support frame (2041) to move to the left. When the left side of the support frame (2041) contacts the second limit switch (207), the walking motor (2043) rotates forward again, repeating the above working process. The walking component (204) moves back and forth multiple times until the rough polishing is completed. Then, the straight pipe (3) and pipe fittings are placed in the prefabrication area (Z3) for pipe prefabrication welding. S4, Straight pipes, prefabricated pipe fittings ① The straight pipe (3) is made of 304 stainless steel seamless steel pipe, the elbow (4) is made of 304 stainless steel large radius elbow, the flange (5) is made of 304 stainless steel flat flange, and the gasket (6) is made of filled polytetrafluoroethylene gasket. ② The process pipeline is used to connect the first storage tank (8) and the second storage tank (9). According to the distance between the first storage tank (8) and the second storage tank (9), the straight pipe (3) is cut and blanked by the cutting machine (101); ③ When a straight pipe (3) is connected to a fitting or another straight pipe (3) at an angle, a pipe beveling machine (102) should be used to open the beveling. The beveling form should be a V-shaped beveling. The beveling gap should be 1-3mm according to the wall thickness of the process pipe. It is strictly forbidden to assemble without beveling or gap. ④ When welding straight pipe (3) to pipe fittings or straight pipe (3) to another straight pipe (3), use electric welding machine (103) to perform argon arc welding for the root pass and argon arc welding for the cover pass, and fill the inside with argon for protection; ⑤ When welding is completed, a weld (7) is formed. The weld (7) is marked, including the pipeline number, weld number, welder number, welding date and other relevant information. ⑥ When the straight pipe (3) is butted, the position of the weld (7) is controlled within 24 meters. If it exceeds 24 meters, add a pair of 304 stainless steel flat welding flanges (5) to ensure that all the inner wall welds (7) of the process pipeline can be polished. S5. Non-destructive testing of welds ① The weld (7) is divided into butt welds and fillet welds. Butt welds are tested by radiographic non-destructive testing, and fillet welds are tested by dye penetrant testing. ② Welds (7) that fail non-destructive testing should be repaired immediately and then subjected to non-destructive testing again. Only those that pass the test can enter the fine polishing area (Z4). S6, straight pipes, fittings, and welds are finely polished. ① The weld (7) is subjected to a rough polishing process. The grinding structure (2032) in the first polishing process uses a 60# polishing pad, the grinding structure (2032) in the second polishing process uses a 150# polishing pad, and the grinding structure (2032) in the third polishing process uses a 240# polishing pad. ② The entire process pipeline is subjected to two rough polishing processes. The grinding structure (2032) in the first polishing process uses a 400# polishing pad, the grinding structure (2032) in the second polishing process uses an 800# polishing pad, and the grinding structure (2032) in the third polishing process uses a 1200# polishing pad. ③ Fix the entire process pipeline detachably on the traveling component (204), start the polishing motor (201) and the traveling motor (2043) to make the process pipeline move slowly towards the polishing motor (201) and perform internal polishing; ④ When the walking motor (2043) is rotating forward, and the support frame (2041) contacts the first limit switch (206), the walking motor (2043) reverses, causing the support frame (2041) to move to the left. When the left side of the support frame (2041) contacts the second limit switch (207), the walking motor (2043) rotates forward again, repeating the above working process. The walking component (204) moves back and forth multiple times until the fine polishing is completed, and then the next polishing accuracy test is carried out. ⑤ After fine polishing, the pipe should be sealed immediately to prevent other debris and impurities from entering the pipe. S7, Polishing precision inspection ① The inner wall polishing of the pipeline is inspected using a TR101 surface roughness tester at the pipeline end, and the roughness is not higher than the design requirements; ② Process pipelines whose surface roughness does not meet the design requirements shall not be allowed to enter the installation area; ③ For process pipelines that have passed the roughness test, operators must not step on or draw on the polished surface at will; ④ For process pipelines that have passed the roughness test, operators are prohibited from hammering, cutting, arc striking, or welding on the polished surface; ⑤ The seals on the process pipelines should be reset immediately after inspection; S8, Pipeline Installation ① The first storage tank (8) and the second storage tank (9) are both installed on the equipment frame (10). After the frame (10), the first storage tank (8) and the second storage tank (9) are installed and aligned, the process pipeline is installed. ② Start installing the process pipeline with the inner wall polished from the equipment port of the first storage tank (8). The butt-welded flat flange (5) on the process pipeline is connected to the flange (5) of the equipment port of the first storage tank (8) by connecting bolts. A gasket (6) is installed between the two flanges (5). The inner opening of the gasket (6) should be flush with the inner diameter of the flange (5) to prevent material from sticking out. ③ During the installation of the process pipeline, a bracket (11) is installed on the process pipeline to avoid stress on the equipment port of the first storage tank (8). The pipeline bracket (11) shall not be welded to the process pipeline whose inner wall has been polished to a qualified standard, and bolts shall be used for connection. ④ After the process pipeline is connected, install a vibrator (12) to prevent the material from being damp and adhering to the inner wall of the process pipeline. The vibrator (12) shall not be welded to the process pipeline whose inner wall has been polished to a qualified standard, and shall be connected by bolts. ⑤ When the process pipeline is installed to the second storage tank (9), check whether the slope of the process pipeline meets the requirements. Only after the requirements are met can it be connected to the second storage tank (9). S9. Pipeline Acceptance ① During the installation of the process piping, the cleanliness of the inside of the process piping should be ensured, and hard tools are strictly prohibited from touching the inside of the process piping; ② Check the tightness of the connecting bolts of the butt-welded flat flange (5), and use a depth micrometer to check the centering of the gasket (6); ③ Check the stability, verticality, and bolt tightness of the bracket (11); ④ Use an angle ruler and a spirit level to measure the horizontality, verticality, and slope of the process pipeline; ⑤ Test run the vibrator (12) by powering it on.

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