Installation method of pipeline modularization system

Abstract

The invention discloses an installation method of a pipeline modularization system. The installation method comprises the steps of modularization segmentation design, factory prefabrication processing, on-site modularization installation, intelligent detection and feedback and the like. Modular prefabricated pipe sections are adopted, two-dimensional code positioning installation is combined, and on-site welding and adjusting time is shortened; and meanwhile, a set machine learning algorithm is adopted to predict a maintenance period and avoid excessive maintenance and sudden fault loss.

Description

Technical Field

[0001] The present invention relates to the technical field of pipeline modularization, and in particular to an installation method of a pipeline modularization system. Background Art

[0002] Modular piping design requires determining module size based on transportation methods, equipment size, and other factors. This allows piping to be designed within the existing framework, and utilizes this framework to support piping, equipment, and platforms, ensuring convenient valve operation and maintenance. In addition to the structural and functional requirements of petrochemical plant processes, modular design incorporates modular design concepts to ensure the modules have relatively independent functions, ultimately ensuring the integrity of the process unit.

[0003] Traditional pipeline installation technology has the following core defects:

[0004] (1) Traditional fixed brackets are non-adjustable, leading to installation errors and inability to adapt to terrain changes and thermal expansion and contraction, which can easily cause pipeline stress concentration and displacement. (2) After installation, manual inspections of parameters such as pressure and temperature are required on a regular basis, which cannot provide real-time warnings for sudden abnormalities and results in delayed processing. (3) Traditional maintenance cycles and resource allocation rely on empirical judgment, and maintenance plans lack data support. Furthermore, the seismic and expansion protection effects are insufficient. Therefore, it is urgent to design an installation method for a modular pipeline system to solve the above problems. Summary of the Invention

[0005] The object of the present invention is to provide an installation method of a pipeline modular system to solve the above-mentioned deficiencies in the prior art.

[0006] In order to achieve the above object, the present invention provides the following technical solutions:

[0007] A method for installing a modular piping system comprises the following steps:

[0008] S1. Modular segmented design: Based on the BIM model, the piping system is divided into several prefabricated segments. The length of each prefabricated segment satisfies the formula L = K·D, where L is the segment length, D is the pipe outer diameter, and K is a coefficient with a value range of 10 ≤ K ≤ 15, ensuring that the segments are suitable for transportation and lifting conditions.

[0009] S2. Factory prefabrication: The steel structure assembly, pipeline welding, and anti-corrosion treatment of the pipe segments are completed at the prefabrication yard. Untreated areas are reserved at the weld joints and labeled with a QR code linking to the BIM model.

[0010] S3. On-site modular installation: Use the QR code to locate the pipe segment installation position, secure the pipe segment with an adjustable bracket, and adjust the bracket height and angle using threaded connections or hydraulic devices. The error is controlled to ΔH ≤ 3mm and Δθ ≤ 1.

[0011] S4. Intelligent detection and feedback: Pressure and temperature sensors are integrated in the bracket to monitor pipeline stress and deformation in real time. When the data exceeds the threshold value P max =1.5P work 、T max =T work +30℃, an alarm is triggered and the support restraint force is adjusted.

[0012] Preferably, the accuracy of the BIM model meets the LOD400 standard and includes pipeline collision detection, net height analysis and maintenance space verification modules. The maintenance space width L is ≥ 500 mm and is calculated by formula H. 实际 ≥H 规范 +50mm to check clear height compliance.

[0013] Preferably, the adjustable bracket includes an anti-slip lock and a shock-absorbing layer. The bracket adjustment adopts a segmented threaded rod and a limit slot structure, and the height adjustment of ±50mm is achieved by rotating the adjustment ring, and a spirit level is provided to assist in calibration.

[0014] Preferably, the factory processing of the prefabricated pipe section includes water pipe pressure test and air duct leakage detection, and the test pressure is 1.5P work， The pressure drop is ≤0.02MPa for 10 minutes, and there is ≤1 light leakage point in every 10 meters of the air duct joints.

[0015] Preferably, the QR code label is associated with the material certification, experimental data and installation coordinates of the pipe section, and the lifting path and connection sequence are automatically generated after being scanned on site by a mobile terminal.

[0016] Preferably, the sensor data is transmitted wirelessly to a cloud platform and combined with a machine learning algorithm to predict pipeline life, generate maintenance plans and optimize maintenance resource allocation.

[0017] Preferably, the pipe section connection adopts a dual structure of a flexible joint and a rubber ring seal, the male and female interfaces of the flexible joint are fixed by a threaded sleeve and a clamping ring, and the rubber ring is pre-filled with quick-setting glue to form a uniform sealing layer after rupture.

[0018] Preferably, the anti-corrosion treatment adopts a combined process of epoxy coating and cathodic protection, the weld reserved area is supplementally coated after installation, and the anti-corrosion integrity is verified by conductivity testing.

[0019] Preferably, the system is suitable for overhead pipelines and underground pipe corridors. Reinforcement rings and windproof cables are added to the overhead pipe sections, and the underground pipe corridors use concrete piers to install beams in layers, with a verticality error of ≤2mm / m.

[0020] Preferably, the pipe section module integrates water supply and drainage, fire protection, electrical bridge and air duct, and the shell size is limited to height ≤ 700mm, width ≤ 2000mm, and the pipe spacing is ≥ 300mm to avoid interference.

[0021] In the above technical solution, the present invention provides a method for installing a modular pipeline system, which (1) uses modular prefabricated pipe sections, the length of which is designed according to the formula L=K·D, K=10-15, and is combined with QR code positioning installation to reduce on-site welding and adjustment time; the construction period is greatly shortened by more than half forty percent; (2) the adjustable bracket achieves a height error ΔH≤3mm and an angle error Δθ≤1° through a threaded / hydraulic device, so that the installation accuracy is adjusted to the ±1mm level; (3) the integrated pressure / temperature sensor Pmax=1.5Pwork, Tmax=Twork+30℃ triggers real-time protection, reducing the failure rate by 50%, or even below 50%; (4) a set machine learning algorithm is used to predict maintenance cycles and avoid excessive maintenance and sudden failure losses. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments described in the present invention. For ordinary technicians in this field, other drawings can also be obtained based on these drawings.

[0023] Figure 1 A schematic flow chart of steps provided for an embodiment of a method for installing a modular piping system according to the present invention.

[0024] Figure 2 A comparative grid schematic diagram is provided for an embodiment of an installation method for a pipeline modular system of the present invention. DETAILED DESCRIPTION

[0025] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0026] like Figure 1-2 As shown, an embodiment of the present invention provides a method for installing a modular pipeline system, comprising the following steps:

[0027] S1. Modular segmented design: Based on the BIM model, the piping system is divided into several prefabricated segments. The length of each prefabricated segment satisfies the formula L = K·D, where L is the segment length, D is the pipe outer diameter, and K is a coefficient with a value range of 10 ≤ K ≤ 15, ensuring that the segments are suitable for transportation and lifting conditions.

[0028] S2. Factory prefabrication: The steel structure assembly, pipeline welding, and anti-corrosion treatment of the pipe segments are completed at the prefabrication yard. Untreated areas are reserved at the weld joints and labeled with a QR code linking to the BIM model.

[0029] S3. On-site modular installation: Use the QR code to locate the pipe segment installation position, secure the pipe segment with an adjustable bracket, and adjust the bracket height and angle using threaded connections or hydraulic devices. The error is controlled to ΔH ≤ 3mm and Δθ ≤ 1.

[0030] S4. Intelligent detection and feedback: Pressure and temperature sensors are integrated in the bracket to monitor pipeline stress and deformation in real time. When the data exceeds the threshold value P max =1.5P work 、T max =T work +30℃, an alarm is triggered and the support restraint force is adjusted.

[0031] Preferably, the accuracy of the BIM model meets the LOD400 standard and includes pipeline collision detection, clear height analysis and maintenance space verification modules. The maintenance space width L ≥ 500mm, and the clear height compliance is verified by the formula H actual ≥ H specification + 50mm; the maximum length of the module L = K·D, where D is the nominal diameter of the process pipeline and K = 10-15; the weight of a single skid-mounted module W ≤ 25t, which meets the low-load road transportation requirements in desert areas.

[0032] Preferably, the adjustable bracket includes an anti-slip lock and a shock-absorbing layer. The bracket adjustment adopts a segmented threaded rod and a limit slot structure. The height adjustment of ±50mm is achieved by rotating the adjustment ring, and a spirit level is equipped to assist in calibration; the adjustable bracket includes: a segmented threaded adjustment rod (M24×2 fine thread), an adjustment stroke of ±50mm, an adjustment accuracy of ≤0.1mm; a horizontal calibration device (built-in dual-axis bubble level, sensitivity 0.02°); an anti-seismic limit structure (rubber damping layer thickness δ=5mm, Shore hardness 60±5).

[0033] Preferably, the factory processing of prefabricated pipe sections includes water pipe pressure testing and air duct leakage detection. The test pressure is 1.5Pwork, and the pressure drop is ≤0.02MPa after maintaining the pressure for 10 minutes. There is ≤1 leakage point in every 10 meters of the air duct joints. BIM optimization includes: model accuracy reaches LOD400 level, pipeline collision detection threshold is ≤5mm; prefabricated module size is standardized to 2m×0.7m×0.3m, with an error of ≤1mm / m; module interface adopts flange pre-welding (flange flatness ≤0.05mm), and the sealing groove is filled with EPDM rubber.

[0034] Preferably, the QR code label is associated with the material certification, experimental data and installation coordinates of the pipe section, and the lifting path and connection sequence are automatically generated after being scanned by a mobile terminal on site; the lifting system includes:

[0035] Four-point hydraulic synchronization mechanism (pressure sensor range 0-10ton, accuracy ±0.5% FS); PID closed-loop control algorithm to achieve suspension point displacement synchronization error ≤ 3mm.

[0036] Preferably, sensor data is transmitted wirelessly to a cloud platform, and combined with a machine learning algorithm to predict pipeline life, generate a maintenance plan, and optimize maintenance resource allocation; the sealing structure includes: a double-pass O-ring (made of fluororubber, wire diameter d=6mm, compression amount 20%); and a self-locking flange bolt.

[0037] Preferably, the pipe section connection adopts a dual structure of a flexible joint and a rubber ring seal, the male and female interfaces of the flexible joint are fixed by a threaded sleeve and a clamping ring, and the rubber ring is pre-filled with quick-setting glue to form a uniform sealing layer after rupture.

[0038] Preferably, the anti-corrosion treatment adopts a combined process of epoxy coating and cathodic protection, the weld reserved area is supplementally coated after installation, and the anti-corrosion integrity is verified by conductivity testing.

[0039] Preferably, the system is suitable for overhead pipelines and underground pipeline corridors. Reinforcement rings and windproof cables are added to the overhead pipeline sections, and the underground pipeline corridors use concrete piers to install beams in layers, with a verticality error of ≤2mm / m.

[0040] Preferably, the pipe section module integrates water supply and drainage, fire protection, electrical bridge and air duct, and the shell size is limited to height ≤ 700mm, width ≤ 2000mm, and the pipe spacing is ≥ 300mm to avoid interference.

[0041] Example 1

[0042] Application of modular pipelines in desert oil and gas fields

[0043] Module division: The device is divided into 6 skids with a maximum size of 6m×3m×3m.

[0044] Bracket adjustment: adopts segmented threaded rod bracket, with height adjustment range of ±50mm, and spirit level to assist calibration.

[0045] Detection system: integrated wireless transmission pressure sensor (range 0-10MPa, accuracy ±0.5%FS), data uploaded to the cloud platform.

[0046] Implementation effect:

[0047] On-site welding was reduced by 80%, and the installation period was shortened to 4 months.

[0048] The sensor can detect pipeline blockage 30 minutes in advance to avoid equipment damage.

[0049] Example 2

[0050] BIM-driven modular installation of urban pipeline corridors

[0051] BIM model accuracy: LOD400 standard modeling, collision detection error ≤5mm.

[0052] Prefabricated module: The integrated pipeline module measures 2m×0.7m×0.3m and integrates water supply, drainage and fire protection pipelines.

[0053] Intelligent lifting: adopts 4-point synchronous lifting system (error compensation ≤ 3mm).

[0054] Implementation effect:

[0055] The verticality error of the pipeline corridor is ≤2mm / m, and the acceptance rate is 99.8%.

[0056] During the operation and maintenance phase, AR technology is used to locate the fault point, and the maintenance response time is shortened to 15 minutes.

[0057] Comparative Example 1

[0058] Traditional 3D modeling construction method, specifically refer to the industrial pipeline modular prefabrication construction method disclosed in application number: CN202311042393.8

[0059] Defect analysis: Design efficiency is low. Traditional 3D modeling requires 3 months to complete collision detection, while modular BIM only takes 2 weeks. The on-site rework rate is high. CN202311042393.8 shows that the traditional method results in 30% of pipelines requiring on-site cutting and adjustment due to drawing errors.

[0060] Comparative Example 2

[0061] Conventional support and hanger installation technology refers to the 21 prefabricated building "Advanced, Mature and Applicable New Technologies" (No. 20): Standard Floor Mechanical and Electrical Pipeline Modular Construction Technology compiled by the Construction Industry Modernization Development Committee of the Architectural Society of China. For details, please refer to the reference:

[0062] Defect analysis:

[0063] Seismic performance: Conventional brackets will displace up to 15mm in a magnitude 5 earthquake, while modular brackets will only displace 5mm.

[0064] Insufficient thermal expansion compensation: Conventional brackets only compensate 40% of the modular design at an 80°C temperature difference, resulting in a 70% increase in the risk of weld cracking.

[0065]

[0066] Comparing Example 1, Example 2, Comparative Example 1, and Comparative Example 2, modularization and intelligent collaboration can greatly reduce the amount of on-site work, and at the same time cooperate with the sensor threshold control P max =1.5Pwork 、

[0067] T max =T work +30℃ can provide good active protection, effectively improving the anti-seismic performance and thermal expansion compensation efficiency.

[0068] The above description is merely illustrative of certain exemplary embodiments of the present invention. It goes without saying that those skilled in the art will be able to modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and description are illustrative in nature and should not be construed as limiting the scope of protection of the claims.

Claims

1. A method for installing a modular piping system, characterized in that: The following steps are involved: S1. Modular segmented design: Based on the BIM model, the piping system is divided into several prefabricated segments. The length of each prefabricated segment satisfies the formula L = K·D, where L is the segment length, D is the pipe outer diameter, and K is a coefficient with a value range of 10 ≤ K ≤ 15, ensuring that the segments are suitable for transportation and lifting conditions. S2. Factory prefabrication: The steel structure assembly, pipeline welding, and anti-corrosion treatment of the pipe segments are completed at the prefabrication yard. Untreated areas are reserved at the weld joints and labeled with a QR code linking to the BIM model. S3. On-site modular installation: Use the QR code to locate the pipe segment installation position, secure the pipe segment with an adjustable bracket, and adjust the bracket height and angle using threaded connections or hydraulic devices. The error is controlled to ΔH ≤ 3mm and Δθ ≤ 1. S4. Intelligent detection and feedback: Pressure and temperature sensors are integrated in the bracket to monitor pipeline stress and deformation in real time. When the data exceeds the threshold value P max =1.5P work 、T max =T work +30℃, an alarm is triggered and the support restraint force is adjusted.

2. The method for installing a modular piping system according to claim 1, wherein: The accuracy of the BIM model meets the LOD400 standard and includes pipeline collision detection, net height analysis and maintenance space verification modules. The maintenance space width L is ≥ 500mm and is calculated by formula H. 实际 ≥H 规范 +50mm to check clear height compliance.

3. The method for installing a modular piping system according to claim 1, wherein: The adjustable bracket includes an anti-slip lock and a shock-absorbing layer. The bracket adjustment adopts a segmented threaded rod and a limit slot structure. ±50mm height adjustment can be achieved by rotating the adjustment ring, and a spirit level is equipped to assist in calibration.

4. The method for installing a modular piping system according to claim 1, wherein: The factory processing of the prefabricated pipe section includes water pipe pressure test and air duct leakage detection, and the test pressure is 1.5P work， The pressure drop is ≤0.02MPa for 10 minutes, and there is ≤1 light leakage point in every 10 meters of the air duct joints.

5. The method for installing a modular piping system according to claim 1, wherein: The QR code label is associated with the material certificate, experimental data and installation coordinates of the pipe section, and the lifting path and connection sequence are automatically generated after being scanned by a mobile terminal on site.

6. The method for installing a modular piping system according to claim 1, wherein: The sensor data is wirelessly transmitted to the cloud platform and combined with machine learning algorithms to predict pipeline life, generate maintenance plans and optimize maintenance resource allocation.

7. The method for installing a modular piping system according to claim 1, wherein: The pipe section connection adopts a dual structure of a flexible joint and a rubber ring seal. The male and female interfaces of the flexible joint are fixed by a threaded sleeve and a clamping ring. The rubber ring is pre-filled with quick-setting glue to form a uniform sealing layer after rupture.

8. The method for installing a modular piping system according to claim 1, wherein: The anti-corrosion treatment adopts a combined process of epoxy coating and cathodic protection. The weld reserved area is supplementally coated after installation, and the anti-corrosion integrity is verified by conductivity testing.

9. The method for installing a modular piping system according to claim 1, wherein: The system is suitable for overhead pipelines and underground pipeline corridors. Reinforcement rings and windproof cables are added to the overhead pipeline sections, and concrete piers are used to install beams in layers in the underground pipeline corridor, with a verticality error of ≤2mm / m.

10. The method for installing a modular piping system according to claim 1, wherein: The pipe section module integrates water supply and drainage, fire protection, electrical bridge and air duct. The shell size is limited to height ≤ 700mm, width ≤ 2000mm, and the pipe spacing is ≥ 300mm to avoid interference.

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