Installation steps:
1. Check the qualified performance of all built-in electric heater equipment.
2. Assemble the pay-off stand. Set up the pipeline threading tractor.
3. At the selected point of the oil pipeline outside the wellhead (the vertical part above the ground), an arc-shaped opening is cut by gas cutting according to the arc shape of the DN55; 30-degree miter pipe provided by the supplier. Grind the groove and repair the gas cutting burr inside the pipe, and weld with the 30-degree mitered pipe.
4. Place the looped element MI heating cable and temperature measuring cable on the pay-off rack respectively (the end of the product is coiled on the outside when the product leaves the factory), and first pass the tail tip of the heating cable into the spherical pipe passer On the screw holes.
5. Slowly penetrate the pipeline tow bar into the pipeline and bring in the traction wire. Until it reaches the predetermined outlet of the end of the pipeline.
6. Connect the traction wire rope to the spherical pipe threader.
7. Rotate the pay-off stand, slowly release the componentized MI heating cable and straighten it, so that it will slowly and smoothly penetrate the pipe under the traction of the steel cable. (If the distance is too long, intercom communication equipment is required to coordinate and contact the command.) Note: If the temperature measurement at the end of the pipe is used, the temperature measurement cable needs to be passed through the spherical pipe piercer and brought into the pipe at one time.
8. There is also a construction method (referred to as B method, suitable for pipelines within 500m), which is to insert the pipe draw rod head and the spherical pipe piercer (specially made by the supplier), and the pipeline draw rod is brought into the pipeline at the same time Component heating cables, etc., after laying in place, withdraw the pipeline tow rod, the head of the pipeline tow rod and the spherical pipe piercer will be automatically separated, and the spherical pipe piercer will stay in the pipe.
9. The current pipeline drawbar is 500 meters long, so the pipe excavation relay method should be used for the part that exceeds the length. (The pipe diameter is large, and the distance is long. Air blowing, water pressure top, or rocket payoff can be used)
10. The temperature measuring cable and the heating cable enter the pipe in the same direction. Bundle the temperature measurement cable and fix it on the heater cable when you are in the same industry. The best distance between the bindings is 500mm, and the cable should be bundled while piercing the tube until the piercing is completed. (The situation with auxiliary electric heater is the same as this)
11. Check the insulation of the built-in electric heater. If the insulation is good, you can proceed to the next operation, otherwise, you should do the treatment to restore the insulation in time.
12. Place a gasket on the flange cover, and pass the flange cover of the oil channel mitre pipe through all heating cables and temperature measurement cables. Then tighten the mechanical seals of the heating cables and temperature measuring cables one by one.
13. Tighten the flange cover with bolts. (Some of the wires are too long, bend and store in the thick tube in advance)
14. Open the wellhead oil valve, loosen the bleed screw, and discharge the air in the 30° miter pipe.
15. Install the explosion-proof junction box body on the flange cover.
16. Test the insulation of the built-in electric heater again.
17. Install the temperature control box in place.
18. Lay and connect all cables between the temperature control box and the junction box. Among them, the power cable should select the appropriate cross section and core number according to its current carrying capacity and actual load rated current.
19. Connect the external cables, etc. with the leads in the junction box according to the provided drawings (in the packing box).
20. After commissioning and trial operation, complete all the follow-up work to clear the site.
Installation notes:
1. If opening relay holes, you can choose wasteland or ridge to reduce the impact on farmland crops.
2. The relay hole should be opened by a tapping machine, and the complete orifice plate can still be welded back to the opening.
3. When feeding the heating cable into the pipe, the heating cable should be slow and evenly applied. If there is an obstacle, do not apply force. Return a little and then feed it slowly. (When using the B method, pay attention to the rod and the heating cable must be retreated synchronously when returning!)
4. The control box should be placed in a place that is easy to manipulate and easy to observe.
5. The control box should be installed vertically on the wall or on the ground, and the enclosure should be electrically grounded.
6. The distance between the control box and the release point of combustible substances should meet the requirements of relevant regulations.
7. Cables entering the junction box and temperature control box should wear protective metal hoses.
8. The MI heating cable of the construction component can not be bent hard or excessively.
Debugging and operation
Before debugging, conduct a general test of the insulation of the heating cable, and its value should be 10MΩ/500V or more, and check the correctness of the wiring. After the above preparations are completed, you can power on and debug.
The steps to start the system are as follows:
1. Turn on the power supply of the control box.
2. Open the box door and close the main circuit breaker and main circuit breaker. At this time, the red light (system power) is on.
3. Set the desired temperature on the panel of the temperature controller, and then turn the “Auto/Manual” knob to “Auto“, and the system enters normal operation. When the temperature measured by the temperature controller is lower than the set temperature lower limit, the contactor is closed, the heating cable is working, and the green light is on. When the measured temperature reaches the upper limit of the set temperature, the contactor opens, the heating cable stops working, and the red light is on. When the measured temperature exceeds the set alarm temperature value, the alarm will sound and the yellow light will be on.
4. When auxiliary heating is needed, turn on the auxiliary heater breaker, and then turn the auxiliary heating switch on the operation panel to the “run” position to start auxiliary heating. When the heating power is above 30Kw, it is equipped with a phase ammeter.
The steps to stop the system are as follows:
1. Disconnect the circuit breakers of the main heater and auxiliary heater.
2. Cut off the main power supply to the control box.
Note: When the yellow light is on, it means that the system has generated an over-temperature alarm, and the system will self-lock to make the contactor in a disconnected state. At this time, the cause of the over-temperature should be found in time, and the fault should be eliminated. After troubleshooting, you must turn the “reset” knob to “reset” before it can be put into operation again. Warning: The operation and maintenance personnel must strictly follow the operation instructions to protect the normal operation of the equipment.
