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The diversity of industrial media requires the control of pressure and temperature during the production process, which imposes extremely stringent requirements on the pipelines used in the chemical industry. Chemical companies put forward many special requirements for the pipeline system in specific application places, such as: heating pipes, vacuum pipes, pipes for transporting solid materials, or sanitized pipes.
How can we best use these equipment assets? Mr. Mathias Dönnecke, the project leader of Franke+Pahl, sums up the experience of his own preventive maintenance program. “When the material used in the piping system is not the best material for the medium to be transported, then this will be applied in practice. In the course of a problem, people often concentrate on the medium being transported, often neglecting the corrosion and impact of the surrounding soil and gas environment on the pipeline.The environment in which the equipment is installed can bring about the outward direction. The corrosion inside."
In the modern technological transformation of process equipment, people tend to overlook whether the old pipeline meets the changes in the current process medium. Mr. Dönnecke added: "To really avoid these problems, maintenance personnel must have relevant process knowledge."
In order to be able to develop the best pipeline maintenance program and better meet the requirements of the piping system, it is first necessary to understand the overall situation of the pipeline system as soon as possible. Although conventional pipe system calculations can provide a lot of detailed information, this calculation is time-consuming and labor-intensive. Based on years of experience in pipeline system analysis, experts from TüV Süd have developed a set of methods and procedures for saving time and money for efficient inspection and evaluation of piping systems.
Figure 1 Mr. Jan Wegner, working at Leuna refinery, said that the Pipeline Technical Service Company is responsible for the monitoring, monitoring and maintenance of the 700km pipeline of the plant.
The service life of even well-designed piping systems is limited. They will age over time, require regular maintenance, and require repairs and modifications if necessary. "The use of non-destructive testing technology can effectively detect problems and hidden dangers that are not easily detected by human eyes," said Reiner Lemke, head of Tectrion's industrial technology service department. This ray inspection method is a method of using an image to display the different characteristics of a material. With this method, it is possible to check for flaws in the piping system that are defective in welds, cracks, or material strength. In order to clearly define and distinguish different materials, experts used X-ray fluorescence analysis.
Karl Inspection Instrumentation Design Company designs and manufactures on-line monitoring ultrasonic corrosion and/or corrosion detection systems for pipeline technology and inspection personnel. In order to prevent underground pipes from being damaged by corrosion, V&C recommends cathodic protection and corrosion protection. Cathodic protection Anti-corrosion measures can reduce the potential difference between the pipeline and the soil, reducing the rate of corrosion to a point where no protective measures are necessary. V&C company specially conducted cost accounting for this, and the accounting results showed that the funds with more cathodic protection accounted for only 4%~15% of the pipeline system investment. Rolf Weber believes that infrared thermal imaging technology is the most valuable method for non-destructive and non-contact inspection of pipeline systems. This thermal imaging detection technology can detect hidden dangers that most human eyes cannot see, so that effective measures can be taken in time to avoid costly shutdowns and accident losses, and the cost of using this technology can be quickly recovered.
The service life and operating reliability of the piping system are related to the dynamic changes in the production process. For example, intense vibrations caused by parts (such as pumps) and internal pressure (pressure shock). Because the vibration amplitude and frequency play a decisive role in the material's fatigue speed. After using a pipe damper, the vibration amplitude and frequency can be significantly reduced. For example, a Visco shock absorber developed and manufactured by Gerb Company was used.
BIS Maintenance Südwest is dedicated to the design and development of equipment maintenance software that provides integrated solutions for mobile maintenance, dynamic monitoring and damage calculations, and further improved energy efficiency. They successfully launched the Steam Pipeline Monitoring System (SPM). With this software system, the load condition of the pipeline can be continuously measured in the horizontal and vertical directions according to the stress-position detection method. The weak links of the pipeline system can be determined by on-line inspection of the places where the stress is loaded in the pipeline system.
Bardenhagen can provide users with effective technical support in the event of a leak in the pipeline system. Their technicians will examine the leakage point of the piping system and make a suitable cover at the leakage point or a sealing cover for the tightly sealed flange connection. Seal the leaked area with the cover and the seal cover, and fill the cover with a sealant compatible with the nature, pressure and temperature of the leaked medium. The sealant self-drys and solidifies, so that the leak can be blocked until the next time the equipment is overhauled, a complete repair of the pipe and flange is performed. Insituform has developed a pipeline lining technology that can be used as an "inserting agent for internal use." This technique applies a fiber-reinforced material coated with a resin material to an inner wall of a pipe by using an impregnated lining that conforms to the shape of the hose. This material is automatically cured and fixed to achieve "plugging." According to the company, this lining patch technology is the most economical solution for repairing pressure pipes, conveying corrosive media pipes, or geothermal pipes.
When cleaning pipelines, operators also have many different pipeline cleaning technologies available. The Comprex pipe cleaning technology developed by Hammann is an ideal solution for cleaning complex fluid delivery piping systems. This pulsed method of flushing is accomplished by blowing controlled controlled air into a slow-flowing stream of water. This will appear in the piping system "water flow block" and "air block", these "blocks" to wash the pipe at a speed of 20m/min. They have a great deal of scouring force against the wall of the pipe, which can wash down the deposits adhering to the pipe wall and send it out of the pipe system. When the attached solid material of the pipe is very stubborn, it is also possible to input a solid auxiliary material having a denuding effect, so that all the solid attachments are cleaned.
summary
In the maintenance of the process equipment piping system, the maintenance of the piping system must be considered from an overall perspective. Only after a thorough understanding and investigation of all the factors that may affect the pipeline system can we ensure that the process equipment piping system continues to function continuously.
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Chemical and pharmaceutical companies involve several long pipelines in their production plants. These pipelines can supply raw materials for production equipment and discharge the waste generated during the production process. These pipelines are the “lifelines†of process equipment. How can we guarantee the reliability and availability of process equipment pipelines? PROCESS magazine reported on fault diagnosis and maintenance of pipeline systems.