Educational literature for external pipeline installers. Methodical manual "technological pipelines"

Unified Tariff and Qualification Directory of Works and Professions of Workers (UTKS), 2019
Issue No. 3 ETKS
The release was approved by Order of the Ministry of Health and Social Development of the Russian Federation dated 04/06/2007 N 243
(as amended: Orders of the Ministry of Health and Social Development of the Russian Federation dated November 28, 2008 N 679, dated April 30, 2009 N 233)

Process pipeline installer

§ 247. Installer of process pipelines of the 2nd category

Characteristics of work. Cleaning of fittings, bolts and studs from preservative grease. Washing of glass equipment, glass pipes and fittings to them. Preservation of pipe ends. Installation and removal of safety plugs and plugs on pipes. Sorting of pipes, fittings and fastenings.

Must know: types of pipes and parts of process pipelines and fittings; types of glass pipes, fittings for them and glass equipment; types of supports used for laying pipelines; pipeline fastening means; purpose and rules for using metalwork tools; methods for measuring pipe diameter.

§ 248. Installer of process pipelines of the 3rd category

Characteristics of work. Pipe etching. Etching of glass equipment, glass pipes and fittings for them. Drilling or punching holes. Installation of pipelines from glass pipes with a diameter of up to 25 mm. Degreasing of parts and oxygen pipeline pipes.

Must know: assortment of pipes and pipeline parts and fittings; assortment of glass pipes, fittings for them and glass equipment; ways chemical cleaning internal surfaces of parts and pipelines; methods for chemical cleaning of equipment made of glass, glass pipes and fittings for them; methods for degreasing parts and oxygen pipeline pipes; types of pipeline parts, gaskets and packings; fittings device; device and rules for using the rigging equipment used; rules for installing pipelines made of glass pipes with a diameter of up to 25 mm; pipe slinging methods; rules for handling and transporting gas cylinders; types of supports used for laying pipelines.

§ 249. Installer of technological pipelines of the 4th category

Characteristics of work. Installation of pipelines with a diameter of up to 200 mm for a nominal pressure of up to 4 MPa (40 kgf/cm2) with installation of fittings. Conducting hydraulic and pneumatic testing of installed pipelines. Installation of hydraulic and electric drives fittings. Beading, beading and joining for welding of pipes made of polyethylene, vinyl plastic, aluminum, copper and brass. Installation and testing of pipelines made of glass pipes with a diameter of over 25 to 40 mm. Installation of glass fittings and shut-off valves. Cutting glass pipes on a machine. Cleaning of welded seams for anti-corrosion coatings. Welding of polyethylene and vinyl plastic pipes. On-site production of parts for pipeline elements made of glass, polyethylene, spirally reinforced from polyvinyl chloride, vinyl plastic, aluminum, copper and brass.

Must know: properties of metals; rules for laying and conducting hydraulic and pneumatic testing of pipelines with a diameter of up to 200 mm for a nominal pressure of up to 4 MPa (40 kgf/cm2); rules for installing pipelines made of glass pipes with a diameter of over 25 to 40 mm; rules for testing pipelines made of glass pipes; rules for slinging pipe assemblies and blocks; methods of giving signals when installing pipelines with cranes; tolerances when preparing joints for welding; permissible gaps and types of edges when preparing pipes for welding; methods for installing non-metallic pipelines.

§ 250. Installer of process pipelines of the 5th category

Characteristics of work. Marking places for laying pipelines. Installation of fittings, tees and sectional bends. Joining of pipes with a diameter of over 200 to 1200 mm with flanges. Installation of pipelines with a diameter of up to 200 mm for a nominal pressure of over 4 to 9.8 MPa (40 to 100 kgf/cm2) with installation of fittings. Installation of pipelines with a diameter of over 200 to 400 mm for a nominal pressure of up to 4 MPa (40 kgf/cm2) with the installation of fittings. Installation of U-shaped, gland and lens compensators with a diameter of up to 400 mm. Installation of benchmarks for measuring thermal expansion and metal creep. Assembly of rubberized, plastic pipelines. Installation and testing of pipelines made of glass pipes with a diameter of over 40 mm. Carrying out installation work using rigging equipment. Installation of hydraulic and electric valve drives.

Must know: rules for laying pipelines with a diameter of up to 200 mm for a nominal pressure of over 4 to 9.8 MPa (40 to 100 kgf/cm2), types of supports and fastenings for them; types of compensators and rules for their installation; rules for conducting hydraulic and pneumatic testing of pipelines; rules for using rigging equipment when performing installation work; rules for installing pipelines made of glass pipes with a diameter of over 40 mm; installation rules and technical requirements requirements for pipelines with a nominal pressure of up to 9.8 MPa (100 kgf/cm2).

§ 251. Installer of process pipelines of the 6th category

Characteristics of work. Installation of U-shaped, stuffing box and lens compensators with a diameter of over 400 mm. Carrying out measurements of the laying of process pipelines at the installation site, drawing up sketches for the preparation and laying of pipelines. Installation of remote valve drives. Installation of pipelines with a diameter of over 200 to 600 mm for a nominal pressure of over 4 to 9.8 MPa (40 to 100 kgf/cm2) with installation of equipment. Installation of pipelines with a diameter of over 600 mm, regardless of pressure, with installation of fittings. Installation of pipelines for nominal pressure over 9.8 MPa (100 kgf/cm2) regardless of diameter with installation of fittings. Installation of fittings with a diameter of over 600 mm, regardless of pressure, or for a nominal pressure of over 9.8 MPa (100 kgf/cm2), regardless of diameter. Installation of glass vacuum, evaporation, circulation devices, etc.

Must know: types of flange connections on special gaskets (lens, metal, etc.) and special coupling connections (ball on cone); rules for laying pipelines for nominal pressure over 9.8 MPa (100 kgf/cm2); methods for taking measurements of pipeline laying sites and rules for making sketches of parts; methods of installing pipelines in blocks; rules for installing pipelines made of alloy steels; installation rules and technical requirements for pipelines for nominal pressure over 9.8 MPa (100 kgf/cm2); installation rules for installed glass devices.

§ 252. Installer of process pipelines of the 7th category

Characteristics of work. Performance complex work with the presentation of strict standards for assessing the quality of work during the installation of pipelines of active circuits of nuclear power plants and main steam pipelines. Installation of pipelines made of corrosion-resistant steels of the austenitic class. Installation of pipelines made of clad steel. Assembly of butt joints with different wall thicknesses. Installation of pipelines in large blocks. Performing cold tensions. Piping of control panels and equipment according to drawings and models. Installation of steam pipelines at steam temperatures of 450 °C and above. Performing steam purges.

Must know: rules for the installation of process pipelines at nuclear power plants, main steam pipelines, pipelines made of clad steel; methods for installing pipelines with large-sized blocks; rules for laying out the route for laying pipeline axes according to drawings and models; methods for performing steam blowing.

Secondary vocational education required.

P. P. Alekseenko, L. A. Grigoriev, I. L. Rubin.
Fitter's Handbook technological equipment

Series

reference books for workers

Founded in 1969

Under general editorship

Ph.D. tech. Sciences P.P. Alekseenko

MOSCOW "MECHANICAL ENGINEERING"

Authors: P. P. Alekseenko, Ph.D. tech. Sciences, L. A. Grigoriev, Ph.D. tech. Sciences, I. L. Rubin, Ph.D. tech. Sciences, V.I. Golomnov, Ph.D. tech. Sciences, E. N. Isakov, Ph.D. tech. Sciences, V. A. Kalugin, Ph.D. tech. sciences

Reviewer Dr. V. A. Apanyakin

Issues of technological preparation of production, methods and techniques of metalwork, assembly, auxiliary and main installation work are outlined. Provides information about the composition and technological structure work performed during installation of equipment industrial enterprises. Considerable attention is paid to technological and metrological ensuring accuracy. Are given specifications tools, machines and devices used by installers, as well as modern principles of organizing the effective work of teams.

For fitters of industrial technological equipment; may be useful for students of technical schools and vocational schools.

Handbook of a fitter of technological equipment/P. P. Alekseenko, L. A. Grigoriev, I. L. Rubin and others; Under general ed. P. P. Alekseenko. - M.: Mechanical Engineering, 1990. -704 p.: ill. - (Series of reference books for workers).

ISBN 5-217-01124-6

© P. P. Alekseenko, L. A. Grigoriev, I. L. Rubin et al., 1990

Preface

Chapter 1. Technological fundamentals of installation industrial equipment(P. P. Alekseenko, V. I. Golovanov)
1. Features of installation production
2. Technological processes and installation operations
3. Documentation for installation work
4. Preparation of work and increasing the installation manufacturability of equipment
5. Organization of the installation site

Chapter 2. Preparatory and auxiliary work (P. P. Alekseenko, V. I. Golovanov)
1. Acceptance and preparation of equipment for installation
2. Acceptance of the construction part of the facility
3. Pre-installation consolidation of equipment into blocks
4. Installation of foundation bolts

Chapter 3. Characteristics of accuracy and the basis for ensuring it during installation (P. P. Alekseenko)
1. General Provisions
2. Metrological assurance of accuracy
3. Technological assurance of accuracy
4. Geodetic justification installation

Chapter 4. Tools for metalwork and assembly work (L. A. Grigoriev, P. P. Alekseenko)
1. Marking and impact tool
2. Clamping tool
3. Hand tools for cutting and processing metal
4. Hole making tool
5. Thread cutting tool
6. Hand tools for assembling threaded connections

Chapter 5. Measuring instruments during installation (P. P. Alekseenko, L. A. Grigoriev)
1. Metrological characteristics of measuring instruments
2. Measures
3.Measuring tool
4. Instruments for linear measurements
5. Instruments for measuring angles
6. Devices for controlling the shape and location of surfaces

Chapter 6. Manual and portable machines (I. L. Rubin)
1. General information
2. Hand drilling machines
3. Hand grinders
4. Manual specialized machines
5. Manual threading machines
6. Manual machines impact and shock-rotational action
7. Other machines and auxiliary devices
8. Pipe bending devices
9. Organization of instrumental facilities
10. Operation, Maintenance and repair of manual machines

Chapter 7. Mechanical work (L.A. Grigoriev)
1. Marking blanks and parts
2. Straightening, straightening and bending
3. Chopping, cutting and filing
4. Drilling, reaming, countersinking and countersinking
5. Thread cutting
6. Scraping, lapping, finishing and polishing
7. Soldering and tinning
8. Riveting, pipe flaring and gluing
9. Preparation of parts (blanks) for welding

Chapter 8. Assembling standard units (L. A. Grigoriev, P. P. Alekseenko)
1. Threaded connections
2. Connections with guaranteed interference
3. Keyed and splined connections
4. Couplings
5. Bearings
6. Gears

Chapter 9. Rigging equipment and lifting operations (E. N. Isakov)
1. Ropes and slings
2. Blocks and pulleys
3. Mounting winches and anchors
4. Cranes and special rigging equipment
5. Hoists and portable winches
6. Jacks for rigging work (I. L. Rubin)

Chapter 10. Installation and securing of equipment (P. P. Alekseenko, V. A. Kalugin)
1. Equipment installation methods
2. Adjustment of equipment position during alignment
3. Securing equipment

Chapter 11. Testing and commissioning of equipment (V. I. Golovanov, P. P. Alekseenko)
1. Types and composition of individual tests
2. Features of testing equipment of various types
3. Comprehensive testing and commissioning of equipment

Chapter 12. Rationing, organization and payment of labor for installers (V. I. Golovanov, P. P. Alekseenko)
1. Labor organization of installers
2. Economic accounting and economic incentive funds
3. Indicators of labor efficiency of teams
4. Rationing and payment of labor for installers
5. Payroll Basics

Bibliography
Subject index

PREFACE

Scientific and technological progress is associated with the re-equipment of everything National economy, rapid growth and updating the technological equipment of industrial enterprises, which in turn creates the need to improve technology, improve quality and reduce equipment installation time.

Installation of equipment - the most important stage production process of construction of new and technical re-equipment of existing workshops of industrial enterprises. It is inextricably linked with all previous technological processes for manufacturing equipment and is the final stage of assembling individual machines and units of entire lines and installations at the site of their operation. The timing of mastering the production of new types of products and the operability of technological equipment largely depend on installation.

The variety of types of installation technological processes, the complexity of the equipment being installed, which is usually unique, and the specific conditions of the installation site require workers to have deep professional knowledge, highly qualified and proficient in related specialties.

The purpose of publishing this handbook is to provide installers with the necessary information on modern technology performing both the entire complex of installation work and individual plumbing, rigging, assembly and control operations, installation work, alignment, fastening of mounted equipment to the foundations, its testing and commissioning. Considerable attention is paid to progressive means of mechanization of technological processes, tools and devices”, means and methods for ensuring installation accuracy. The issues of organizing and economically stimulating the work of installation teams in modern conditions management.

Download the reference book for a process equipment fitter. Moscow, Publishing House Mashinostroenie, 1990

Preface
Chapter 1. General information about pipelines
§ 1. Purpose and classification
§ 2. Conditional passages. Conditional, working and test pressures
§ 3. Types of pipeline connections
Chapter 2. Pipes and pipeline fittings
§ 1. Steel pipes
§ 2. Cast iron pipes
§ 3. Plastic pipes
§ 4. Glass pipes and pipes made of other non-metallic materials
§ 5. Welded parts steel pipelines
§ 6. Flanges
§ 7. Connecting parts of plastic pipelines
§ 8. Connecting and fastening parts of glass pipelines
Chapter 3. Pipeline accessories
§ 1. Purpose and classification of fittings
§ 2. Acceptance and inspection of fittings
Chapter 4. Tools for the manufacture and installation of pipelines
Chapter 5. Crane and rigging equipment
Chapter 6. Equipment and technology for manufacturing steel and cast iron pipelines
§ 1. Pipe processing
§ 2. Pipe bending
§ 3. Calibration and straightening of pipe ends and parts
§ 4. Assembly of pipeline elements and assemblies
§ 5. Welding of pipelines
Chapter 7. Equipment and technology for the manufacture of plastic pipelines
§ 1. Mechanical processing of pipes and blanks
§ 2. Molding in the manufacture of parts
§ 3. Pipe bending
§ 4. Welding of pipes and parts
Chapter 8. Equipment and technology for installing glass pipelines
Chapter 9. Technical and regulatory documentation for pipeline construction
§ 1. Composition and requirements for technical documentation
§ 2. Installation drawings
§ 3. Detail drawings
§ 4. Regulatory documents
§ 5. Work projects
Chapter 10. Mechanized lines and sections of pipe workshops
§ 1. Mechanized lines for the production of pipeline units
§ 2. Mechanized section for the production of sectional bends
§ 3. Mechanized lines and areas for the production of pipeline sections
§ 4. Mechanized line for anti-corrosion pipe insulation
§ 5. Mechanized section for the production of parts and assemblies of plastic pipelines
Chapter 11. Pipeline installation technology
§ 2. Route layout
§ 3. Installation of supports and hangers
§ 4. Installation of pipelines
Chapter 12. Testing and commissioning of pipelines
§ 1. Preparatory work
§ 2. Testing of process pipelines
§ 3. Testing of external water supply and sewerage pipelines
§ 4. Testing of heating network pipelines
§ 5. Testing of gas pipelines
Chapter 13. Labor costs and the cost of pipeline work
§ 1. Rationing and remuneration
§ 2. Cost of installation of pipelines
Applications
Bibliography

1. Introduction.

2. Types of purpose of the device used in the installation of external pipelines.

3. Promising types of welding.

3.1.Methods that increase labor productivity.

3.2.Welding methods that increase labor productivity.

4. Labor protection.

4.1. Electrical safety.

4.2. Fire safety.

6. Literature.

Introduction.

During the construction of enterprises in the oil, chemical, food, metallurgical industries, as well as facilities for the production of mineral fertilizers and the agro-industrial complex, a significant amount of work consists of the production and installation of process pipelines.

In the total volume of installation work, the cost of installing process pipelines reaches 65% in the construction of enterprises in the oil and petrochemical industries, 40% in the chemical and food industry, and 25% in the metallurgical industry.

Process pipelines operate in a variety of conditions, are exposed to significant pressures and high temperatures, are subject to corrosion and undergo periodic cooling and heating. Their design, due to the expansion of the unit capacity of facilities under construction, is becoming more and more complex from year to year due to an increase in the operating parameters of the transported substance and an increase in pipeline diameters.

For the construction of process pipelines, especially in the chemical and food industries, they have increasingly begun to use polymer materials. The increase in volumes and scope of application of these pipes is explained by their high corrosion resistance, lower weight, ease of processing and welding, low thermal conductivity and, as a consequence, lower costs for thermal insulation.

All this requires installers to have deeper knowledge, strict compliance with the requirements for the use of various materials, compliance with rules and special technological requirements for the manufacture and installation of pipelines.

In recent years, industrial methods of pipeline work have been introduced on a large scale, which provides a 40% increase in labor productivity and reduces the amount of work performed directly at the installation site by 3-4 times, while the time required for pipeline installation is reduced by three times. The essence of the industrialization of pipeline work is the transfer of all pipe procurement work to factory conditions, with the aim of transforming construction production into a comprehensive mechanized process of installing objects from ready-made units and factory-made blocks.

Types of purpose of devices used in the installation of external pipelines.

External pipelines are installed in enlarged blocks or sections. Installation of inter-shop pipelines with separate pipes is allowed only in cases where, due to cramped conditions, laying in sections becomes impossible.

Based on the type of enlargement, blocks can be made from building structures, pipeline and combined.

Blocks from building structures are used in the construction of prefabricated reinforced concrete and metal overpasses of beam and truss types. The block of building structures of beam reinforced concrete overpasses includes beams, traverses, transition bridges and their fences, and metal truss - trusses, upper and lower beams, tie elements, transition bridges and their fences.

The pipeline blocks may include: straight sections of pipelines, consisting of one or several sections (within the temperature block); satellites; U-shaped, lens or gland compensators; thermal insulation.

A combined block is an overpass span assembled before lifting with installed and secured pipeline blocks.

The choice of the type of block and the degree of its enlargement is determined by the PPR depending on the design solutions of the overpasses, the number and location of pipelines, their diameters, the presence of lifting mechanisms and Vehicle, as well as local conditions of work. Installation is usually carried out using pipeline and combined blocks.

Enlarged assembly of blocks is carried out on assembly sites - mobile or stationary, which are located in the operating area of ​​the assembly crane.

A diagram of a moving platform for assembling pipeline blocks up to 60 m long, laid on a metal truss overpass, is shown in Fig. 3. Pipeline blocks are assembled in the following sequence: load, transport and unload fittings, parts, components and sections; install racks or stands; prepare the edges of sections for welding; they rafter sections, lift and place them on racks; assemble and weld joints, control the quality of welded joints; mark the installation locations of the supports and secure the supports; control quality, mark and accept blocks.

When divided into blocks, the length of pipelines laid along separate racks, as well as outside the cross-sectional contour of the overpass, is taken for D y less than 150 mm and more than 400 mm, no more than 36 m, from 200 to 400 mm - no more than 60 m.

When assembling blocks, the installation locations of the supports are marked according to the design (taking into account the displacement of the supports under the influence of thermal expansion), as well as according to the arrangement of support structures taken from nature (taking into account their deviation from the design position). When pre-installation thermal insulation of blocks, uninsulated sections of at least 500 mm in length are left at the pipe joints and at least 250 mm in length at the ends of the blocks. Pre-insulation of steam and hot water, registered by Gosgortekhnadzor, is not permitted.

A diagram of a stationary site for assembling combined blocks laid on a metal truss overpass is shown in Fig. 4. Combined blocks are installed in the following sequence: loaded, transported and unloaded enlarged elements of building structures and pipeline sections; assemble pipeline blocks; lay out and fix the lower beams; install farms; install the upper racks, attach the “Christmas trees”; lay and temporarily secure pipeline blocks placed inside the cross-sectional contour of the block; install upper beams, half-beams and connections of the upper chord; arrange elements of rigidity; mark and accept the block.

Temporary stiffening elements (spacers or connections) must prevent the possibility of breakage and deformation of the blocks during their transportation and installation. The designs and installation locations of such elements are determined by the PPR. Temporary fastening of pipelines in combined blocks is carried out with clamps in places where the pipeline rests on building structures at at least two points for each block.

When installing structures of overpass spans and pipelines, it is necessary to ensure the stability and immutability of the assembled part of the overpass.

Installation work on laying external inter-shop pipelines on separate supports or overpasses is started only after receipt from the construction organization of certificates on full compliance of the supporting structures with the design and technical conditions, as well as verification of the actual performance of these works by representatives of the installation organizations.

For inter-shop pipelines, a route layout report is drawn up. Attached to the act is a list of axes and rotations indicating the signs placed on the racks or painted with indelible paint on the walls.

It is necessary to check the readiness of the building structures of overpass racks (for combined and pipeline blocks laid on separate racks) and spans (for pipeline blocks) for installation and draw up an as-built diagram that takes into account the deviation of elevations and the position in plan of the overpass support structures.

The range of works for the installation of blocks includes: installation of scaffolding; breakdown of pipeline axes; slinging; lifting and installing blocks into the design position; temporary fastening of blocks; unslinging; assembly of installation joints; welding of joints; testing and acceptance of pipelines; sealing thermal insulation joints.

Installation within each temperature block begins only after the installation of intermediate fixed (anchor) racks with welding of all connections.

When laying pipelines located inside the cross-sectional contour of the overpass, pipeline blocks, depending on the type of overpass, can be installed using several methods: preliminary laying of the blocks inside the cross-sectional contour of the overpass before installing the upper tier structures (for prefabricated reinforced concrete two-tier beam-type overpasses); inserting pipeline blocks into the open end of the overpass (for all types of overpasses); inserting blocks into the contour through a specially provided opening in the plane of the upper chord of the overpass (for truss-type metal overpasses).

The installation of overpass span structures begins from the fixed (anchor) post and proceeds in both directions from it.

When assembling pipeline and combined units at stationary assembly sites or in pipe procurement shops, it is advisable to install them directly from vehicles, which eliminates intermediate operations for storing and unslinging cargo. In this case, the blocks are transported directly to the operating area of ​​the installation crane and are gradually installed on the overpass.

Combined blocks of two-tier reinforced concrete overpasses are installed only after completion of installation of all inserts (stage I) and welding of inserts with support posts. Traverses and connections along the upper tier are installed after installing the combined blocks on the lower tier and laying pipelines in it, suspended from the upper tier, if this is allowed by the design of the overpass.

Combined blocks of a metal truss trestle are mounted with one crane 2, with the exception of compensating blocks, which are mounted with two cranes. Combined block 1 is brought into the design position by aligning the mounting holes, marking marks or supporting embedded parts with the corresponding installation locations of previously installed span structures or supports. To avoid impact, the block is positioned by very small movements of the assembly crane, as well as by manually tensioning the braces (at least two) with mounting crowbars, clamps and jacks.

Before alignment, blocks are temporarily secured with mounting bolts, clamps and other equipment. The slings are removed after checking the correct installation and fastening of the mounted blocks. The process pipelines and fittings are finally secured, and the assembly joints are welded after the installation of the section of the overpass that makes up the temperature block. At the same time, the abutting sections and pipeline blocks are mutually displaced until the required gap is formed.

Reinforcing elements of block structures installed for the period of transportation and installation are dismantled only after the block is completely secured in the design position. During large-block installation of external pipelines on overpasses, labor-intensive operations include assembling and welding pipes between blocks, cutting and adjusting joint pipes, as well as adjusting the position of sections during the assembly process.

Installation of inter-shop pipelines in blocks and sections makes it possible to mechanize 80–85% of procurement, assembly and welding, insulation and installation work and significantly improve the quality and productivity of labor.

On newly constructed overpasses, free space is left for laying additional pipeline lines in case of possible expansion of the enterprise and increase in capacity. Additional lines pipelines on existing overpasses are usually laid in separate pipes (Fig. 8). Pipes 5 are lifted by crane 4 and, using tractor 1 or winches and outlet blocks 2, dragged inside the overpass 3.

Promising types of welding.

Methods that increase labor productivity.

Organizational measures to increase labor productivity include: timely provision of welders with serviceable, network-connected welding equipment, welding materials and tools, hoses, cables, special clothing, and personal protective equipment; providing the welder with an equipped workplace and providing safe approaches to it; timely preparation of parts for welding; provision of technological documentation; creation of necessary production and living conditions.

Organizational and technological measures include: timely and quick connection of equipment and troubleshooting; supply of high-quality electrode holders and tools; provision of devices for quick rotation of products or their edging; manufacturing the most efficient structures with a minimum amount of deposited metal in the finished product. Strict implementation of organizational and organizational-technical measures, along with the introduction of progressive forms of labor organization, increases labor productivity by at least 15 - 20%.

If we consider technical events, the implementation of which makes it possible to increase the productivity of welding work, the following should be noted.

· An increase in the welding current density at the selected electrode diameter compared to the passport data allows you to increase the productivity of manual welding by 1.5 - 2 times due to an increase in the welding speed and the depth of penetration of the base metal. The best technical and economic indicators when welding at high conditions are obtained when using electrodes with a diameter of 5 and 6 mm. However, increasing the welding current density above 12 - 14 A/mm 2 when welding with electrodes with a basic coating is not recommended, as this leads to severe spattering of the electrode metal, a decrease in the deposition rate and deterioration in the quality of the weld.

· Increasing the electrode diameter from 3 to 6 mm allows you to increase welding productivity by 3 times (if the optimal welding mode for each electrode diameter is correctly selected). The use of large diameter electrodes (8 and 10 mm) allows welding at increased current and thereby increases the productivity of the process. However, when welding with such electrodes, the mass of the electrode and holder increases, which causes fatigue for the welder. Difficulties arise in ensuring weld root penetration in narrow edge grooves and fillet welds. In addition, when manual welding with high currents, the magnetic blast increases significantly, especially when welding with direct current, which complicates the welding process and leads to a decrease in the quality of the welded joint.

· The use of electrodes with iron powder or other metal additives in the coating is used to increase the deposition rate. The productivity of welding with such electrodes increases by 10–15% compared to welding with conventional electrodes. At the same time it decreases specific consumption electricity (by about 20%)

The introduction of iron powder into the coating increases the deposition rate, increases the transition of the electrode metal into the weld, and improves appearance seam Small additions of iron powder (up to 14%) are used to stabilize the arc, medium and large (up to 50%) are used to increase process productivity. High-performance electrodes usually include electrodes for which the transition of the electrode metal to the weld due to the addition of iron powder to the coating is over 120%, for example, electrodes of the ANO-5 (11 g/Ah), ERS-1 (14 g/Ah) brands. , OZS-3 (15 g/Ah). Electrodes of these brands are suitable for welding only in the lower position.

Welding methods that increase labor productivity.

Submerged arc welding, in contrast to the conventional method of manual welding with a covered electrode (open arc welding), is called electrode welding or deep penetration welding.

To obtain deep penetration, special high-quality electrodes with an especially thick coating are used, for example OZS-3 brand.

The electrode is rested with the visor formed during melting on the metal being welded at an angle of 70 - 85 o to the horizon for better displacement liquid metal from the crater (Fig. 9). When welding, the arc is immersed in the base metal, and the edges of the visor protect the electrode from short circuits. A short arc during immersion welding is maintained automatically due to the support of the coating visor on the base metal. A high concentration of heat with a short arc increases the depth of penetration. When welding with deep penetration, metal loss due to waste and spatter is minimal. Welding is carried out at high welding current and at high speed.

This method is most effective when welding corner and T-joints in the lower position, but it is also used when welding butt joints.

Submerged arc welding requires careful preparation of the product being welded: the surface along the seam is cleaned of rust, the gap between the edges should not exceed 10% of the thickness of the metal of the product.

Deep penetration welding differs from conventional manual welding by a higher welding current and a higher welding speed. In addition, it has the following advantages: the need to hold the electrode suspended is eliminated, which makes the welder’s work easier; good penetration of the root of the seam is ensured; Welding of sheets up to 20 mm thick is possible without bevel of edges; welding skills are acquired within a few days; not required high qualification welder; Labor productivity increases 2–3 times.

Support welding vertical position in the direction from top to bottom can be performed using electrodes of the ANO-9 brand. When applying fillet welds with an 8mm cutter, electrodes with a diameter of 4mm are used. Welding speed 10 m/h.

Welding with a bunch (comb) of electrodes is carried out using the same techniques as manual welding with one coated electrode. The welder simultaneously works with two, three or more electrodes connected into a bundle by applying tacks at the point where they are clamped into the electric holder. The electrodes are connected to each other with soft wire (steel or copper with a diameter of 0.25 - 0.5 mm) along the length in 3 - 5 places, and on top - by welding. In this case, a regular electrical holder is used.

If the design of the electric holder allows you to hold several electrodes, there is no need to connect them at the gripping point.

When welding with a bunch of electrodes, the arc is first excited between one electrode and the workpiece being welded. When this electrode melts so much that the distance from its end to the product becomes large, the arc will go out and reappear between the product and the electrode that is closest to the product. The arc alternately occurs where the distance between the product and the electrode becomes minimal, and gradually melts the electrodes. The process occurs continuously, as in welding with one electrode.

When welding with a bunch of electrodes, the current passes through individual electrodes for a short time, they heat up less than during conventional welding, and this makes it possible to use a higher welding current.

The use of this welding method is very effective in surfacing work.

The disadvantages of electrode beam welding include its unsuitability for vertical and ceiling welding, as well as the complexity of manufacturing electrodes.

Torchless welding differs from conventional manual welding in that the electrode is not fixed in the holder, but is welded to its end. Due to this, the loss of electrodes due to cinders is eliminated, the strength of the welding current increases (by 10 - 15%) and the loss of time for changing electrodes is reduced.

Burnless welding increases labor productivity, but it is not free from disadvantages: it becomes difficult to manipulate the electrode, which, if the welder has insufficient experience, negatively affects the quality of the welded joint; Welding an electrode compared to fixing it in a conventional electric holder is a more complex operation.

Welding with a lying electrode is that the electrode with high-quality coating is not fed into the arc zone, but is placed in the cutting edges (Fig. 10). The arc, excited between the end of the electrode and the metal being welded, moves along the length of the electrode, gradually melting it.

One or several electrodes with a diameter of 6 - 10 mm are placed in the groove. Paper insulation is placed on top and pressed with a copper block.

This type of welding is especially convenient in hard-to-reach places. The length of the electrode is taken to be equal to or a multiple of the length of the seam, and the cross-section of the seam is equal to the cross-section of the electrode rod. With this welding method, one operator can serve several positions.

This welding method ensures high quality weld metal; productivity increases by 1.5 - 2 times compared to manual welding due to the use of large diameter electrodes and a corresponding increase in the welding current; reduces metal loss due to waste and spattering.

Welding with an inclined electrode is welding with a metal electrode, when an electrode with a high-quality coating self-feeds into the arc zone, the lower end of which rests on the product, while the upper end is fixed in a special sliding electric holder (Fig. 11).

The support fixes the device on the surface of the metal being welded using a magnet. As the electrode melts, it moves under its own weight along a guide along the welding line. The electrode coating rests on the workpiece to be welded, ensuring a constant arc length. Top part The visor is longer than the bottom, so the arc deviates towards the product being welded. The cross-section of the seam is regulated by changing the angle of inclination of the electrode.

There is also a known method of welding with an inclined electrode, in which the upper end of the electrode is hinged.

Three-phase arc welding is carried out using special electrodes and electric holders. Manual welding and surfacing are carried out in the following ways: with two electrodes fixed in two holders (Fig. 12, a); two parallel electrodes fixed in one holder (Fig. 12, b). The electrodes consist of two rods located at a distance of 5–6 mm from each other and covered with coating, and the electrode holders have separate fastenings and electrical connections to the electrodes. The ends of the electrodes with one side (cleaned) are separately fixed in the electrode holder. When welding, one phase is supplied to the product, and two phases (separately) are supplied to the electrodes.

Productivity when welding with a three-phase arc compared to conventional single-phase manual welding increases approximately 2 times, but the technique is somewhat more complicated due to the increase in the mass of the electrode and holder. Three-phase arc welding skills are acquired quite quickly.

A three-phase arc is used to weld joints (butts and T-joints) in the lower position. When welding, large beads may form. Therefore, T-joints should be welded “in a boat”. Reducing porosity and increasing penetration depth is achieved by welding using the electrode support method.

When welding with two parallel electrodes clamped in one holder, the angle of inclination of the electrodes to the surface of the plate should be 65–70 o. If the angle of inclination is excessively large, liquid slag and metal flow forward onto the unmolten metal of the plate, as a result of which the penetration depth decreases. At a small angle of inclination, liquid metal and slag are strongly pushed by the arc into the tail part of the weld pool, which disrupts the formation of the seam and increases spattering.

To obtain a wide roller, the electrodes must be given a transverse oscillatory movement, the width of which for longitudinally located electrodes should be no more than two diameters of the electrodes (Fig. 13, a), and for transversely located electrodes no more than four (Fig. 13, b).

When multilayer butt welding of plates with one-sided bevel of the edges, the first layer is performed with paired electrodes located along the seam (Fig. 14, a), and the subsequent ones with transversely located electrodes (Fig. 14, b).

When lap welding plates, the electrodes should be positioned across the seam. In this case, the angle of inclination of the electrodes in the welding direction should be 70 - 75 o (Fig. 15, a) and in relation to the surface of the parts 50 - 60 o (Fig. 15, b). During the welding process, electrodes perform transverse oscillatory movements with an oscillation amplitude of 2.5–3 times the diameter of the electrode.

A three-phase welding arc emits more radiation than a single-phase one, so protective filters should be darker.

Bath arc welding (Fig. 16) is characterized by increased dimensions of the weld pool held in a special form (steel or ceramic). The steel mold is welded to the welded joint, the ceramic molds are made detachable and removed after welding. Used when welding rod products (for example, reinforced concrete reinforcement and rails). Welding is performed with one or more electrodes (Fig.) of the UONI brand. Welding is performed on elevated modes, which provides the necessary heating of the elements being welded to create a large weld pool of liquid metal.

Welding begins at the bottom of the mold, in the gap between the ends of the rods. The electrode is first moved along the gap. During the welding process, the deposited metal must be in a liquid state.

Welding with electric rivets is carried out with the penetration of the upper part by a welding arc without a hole in the top sheet or through a previously prepared hole.

The welding method without a hole is used when the thickness of the top sheet is no more than 2 mm. The need to drill holes in the top sheets limits the scope of electric rivet welding. However, high productivity and ease of assembly of large-sized units when connecting thin sheets with rolled profiles contribute to wide application welding with electric rivets in industry.

In connections with fused holes, the distance between the holes is 100–200 mm, and the hole diameter is 1–2.5 δ (δ is the sheet thickness, mm). Holes are drilled or punched using hole punching presses. When welding, the hole is completely melted with a slight overflow on top. Connections with electric rivets are not very durable.

Electrical safety.

Electrical injuries occur when electric current passes through a person.

A current of 0.1A, regardless of its type, is considered to be fatal to humans. With a minimum resistance of the human body of 600 Ohms, a deadly current value (0.1A) is created at a voltage of only 60V.

The severity of electric shock depends on the magnitude of the current and voltage, as well as on the path of current in the human body, the duration of the current, and frequency (with increasing frequency of alternating current, the degree of damage decreases, alternating current is more dangerous than direct current).

Electrical injuries in industrial environments most often occur as a result of a person touching live parts that are under dangerous voltage.

Dangerous voltage can be step voltage, which occurs when electric current flows into the ground. Current spreading is possible in cases where a broken electrical wire of an overhead network touches the ground or when protective grounding is triggered. If a person finds himself in the zone of current spreading, then a potential difference (step voltage) arises between the leg located closer to the ground electrode and the leg located at a step distance from the ground electrode (0.8 m) and a current circuit is closed from leg to leg. Rubber shoes are used to protect against step voltage.

Rules for safe work with electrical installations.

Premises are divided into three categories according to the degree of danger of electric shock to people:

· especially dangerous (high humidity, air temperature above +30 o C, chemically active environment leading to destruction of the insulation of live parts);

· with increased danger (conductive floors, the possibility of human contact with metal structures and electrical equipment housings, etc.);

· without increased danger (there is no danger of electric shock).

Electrical installations and devices are considered dangerous if their current-carrying parts are not fenced and are located at a height accessible to humans (less than 2.5 m), there is no grounding, grounding and protective disconnections of current-carrying structures (metal enclosures) magnetic starters, “start”, “stop” buttons, etc.).

Requirements for personnel servicing electrical installations.

The rules for the technical operation of electrical installations allow persons of five qualification groups to work on them:

· Qualification group I is assigned to personnel who have not passed the knowledge test according to the Rules for the Technical Operation of Electrical Installations.

· Qualification group II is assigned to persons who have basic technical knowledge of electrical installations (electric welders, electricians, etc.).

· Qualification group III is assigned to persons who have knowledge of special safety rules for those types of work that are the responsibility of this person (electricians, technicians, etc.).

· Qualification group IV is assigned to persons who have knowledge in electrical engineering in the scope of a specialized vocational school.

· Qualification group V is assigned to persons who know the circuits and equipment of their site, etc.

Fire safety.

The reasons that cause fires in workshops are the presence of flammable substances and flammable liquids, liquefied flammable gases, solid combustible materials, containers and apparatus with flammable products under pressure, electrical installations that cause electric sparks during their operation, etc.

There are many reasons for fires: spontaneous combustion of some substances if their storage is unsatisfactory, ignition by flame, electric spark, liquid metal, slag, etc. Based on fire hazard, it is customary to divide production into several categories: A - fire and explosion hazard, B - explosive, C - fire hazard , G and D – non-flammable, E – explosive (there are only gases).

Welding work can be performed in premises of each production category in accordance with the requirements of GOST 12.3.002-75, GOST 12.3.003-75.

Welding work in closed containers must be carried out with special permission from the enterprise administration.

The work procedure for organizing and carrying out welding work in mines and mines is determined by instructions approved by Gosgortekhnadzor.

Prohibited:

· Use clothing and gloves with traces of oils, fats, gasoline, kerosene and other hot liquids;

· Perform cutting and welding of freshly painted structures until the paint is completely dry;

· Perform welding of devices under electrical voltage and vessels under pressure;

· Carry out cutting and welding of liquid fuel containers without special training.

Fire extinguishing agents include water, foam, gases, steam, powder compositions, etc.

When extinguishing fires with water, water fire extinguishing installations, fire engines, and water nozzles (manual and fire monitors) are used. Special water pipes are used to supply water to these installations. For extinguishing fires with water in most industrial and public buildings Internal fire hydrants are installed on the internal water supply network.

Foam is a concentrated emulsion of carbon dioxide in an aqueous solution of mineral salts containing a foaming agent. To obtain air-mechanical foam, air-foam barrels, foam generators and foam sprinklers are used. Foam generators and foam sprinklers are used to equip stationary water-foam fire extinguishing installations. When extinguishing fires with gases and steam, carbon dioxide, nitrogen, flue gases, etc. are used.

Each welding station must have a fire extinguisher, a tank or bucket of water, and a box with sand and a shovel. After completing the welding work, it is necessary to check the work room and the area where the welding work was performed and do not leave open flames or smoldering objects. The workshops have special fire-fighting units, and voluntary fire brigades are created from among those working in the workshop.

Conclusion.

I, Evgeny Anatolyevich Trukhanovich, studied at MGPTU No. 31 for one year, after the 11th grade, during which time I learned how to perform installation and welding work.

He completed his internship in the 15th trust, worked as an installer of external pipelines, and performed restoration work.

I express special gratitude to: Lashchuk G.S., Osipov M.Yu. and special subject teacher Bogansky I.I.

Literature.

1. Vinogradov Yu.G., Orlov K.S. Materials science for fitters. M. 1983

2. Zaitsev A.V., Polosin M.D. Automotive cranes. M. 1983

3. Kikhchik N.N. Rigging work in construction. M. 1983

4. Lupachev V.G. Manual arc welding. Mn. 2006

6. Tavastsherna R.I. Installation of process pipelines. M.1980

A. A Persion K. A. Garus,

laureates of the State Prize of the Ukrainian SSR

Provides reference data on the manufacture and installation of pipelines for various purposes (technological, water supply systems, sewerage, etc.). Are given short description and technical characteristics of equipment and special devices used in the manufacture of sections, assemblies of steel pipelines, welded and molded parts of plastic pipelines, cleaning, priming, anti-corrosion insulation of pipes and installation of pipeline systems. Regulatory materials are given as of January 1, 1987.

For workers and foremen involved in pipeline installation.

Reviewers: engineers A. M. Meged, B. E. Aizin

Editorial office of literature on special and installation works in construction

Head edited by S. I. Sotnichenko

PREFACE

The main task of capital construction in the XII Five-Year Plan is the creation and accelerated renewal of fixed assets of the national economy, intended for the development of social production and solving social issues, and a radical increase in the efficiency of construction production.

For her successful implementation The main directions of economic and social development The USSR for 1986-1990 and the period until 2000 provides: “Consistently carry out further industrialization construction production, turning it into a single process of constructing objects from factory-made elements. Go to a complete supply of engineering and technological equipment to construction sites in enlarged blocks... Reduce the amount of work performed manually by approximately 25 percent.”1

Resolutions of the Central Committee of the CPSU and the Council of Ministers of the USSR “On further improvement of management of the country’s construction complex” and “On measures to improve the economic mechanism in capital construction” plan to implement a number of effective measures to actually shorten the investment cycle, improve the quality of work, and significantly increase the productivity of builders through comprehensive mechanization and industrialization of construction processes, widespread introduction into practice of effective products and materials.

Perestroika construction complex countries aims to accelerate implementation production capacity based on the widespread introduction into practice of the achievements of science and technology.

To industrialize the construction of pipelines for various purposes, construction and installation organizations of the Ukrainian SSR are constructing new ones, reconstructing and technically updating existing pipe production shops. They install advanced equipment for cutting pipes, assembling units and sections, mechanized welding, quality control of welds, etc.

The use of ready-made units and sections, centrally manufactured in pipe procurement shops, makes it possible to simplify the technology and organization of pipeline installation and reduce the volume of labor-intensive work performed at the construction site by 2.5-3 times.

The directory systematizes the progressive developments of research and design institutes, production organizations in the field of manufacturing and installation of pipelines for various purposes, in particular the Institute of Electric Welding named after. E. O. Patoia Academy of Sciences of the Ukrainian SSR, VNII-moitazhepetsstroy, Giproieftespetsmontazh, All-Union Institute of Welding Production.

Chapters 1-12 were written by A. A. Persioi, chapter 13 by K. A. Garus.