In recent years, the concept of modular design has been extended from the electronics industry to various manufacturing industries, and it’s widely used in design domains such as machine tools, electronic products and aerospace, etc. The fructose ion-exchange project designed by Myande has achieved the expected results by adopting modular design.
The basic steps of modular factory construction:
Determine the module specification→Modular design→Manufacture→Long-distance transportation→Field installation→Modern factory.
Process design is the core of modular design. The key to applying the modular design concept to the pipeline design is the standardization and systematization of process flow and equipment design. Design standardization is the premise of modular design. In the process of modular design, the process flow, process conditions, equipment specifications and equipment type need to match the conditions of modular design, equipment materials and related manufacturing standards should also meet the requirements, at the same time, the geological and meteorological conditions of construction site shall be taken into consideration. In other words, modular design should give full consideration to different manufacturing standards, geological and meteorological conditions.
In addition, it is important to pay attention to the following points when designing the pipeline layout:
(1) The pipeline layout should be classified according to type and size, arrange plan diagram.
(2) Typical pipeline layout design of general equipment and final-designed equipment.
(3) Applying modular partitions to the equipment layout drawing, and which with high degree modularization is preferred for partition modular design.
(4) Modular design of pipeline material database.
(5) Modular design of pipeline standard support and hanger.
Implementation steps of pipeline modularization:
1. Work in the design stage
Select the pipeline module→Define the pipeline module→Determine welding seam type of pipeline module→Forming serial products after a comprehensive analysis of the performance of each functional unit. In addition to the serialization of functional modules, customers' special needs should also be considered in different engineering projects, which requires the balance between standardization and special requirements in the design process.
Publish the construction drawings of the pipeline module. Formulate the procurement plan of valves and pipelines in the module according to the project construction plan, and determine its supply time and place.
Fig.1 is an example of 3D design model of the pipeline module.
2. Pipeline module manufacturing and hydraulic test
The prefabrication of the pipeline module factory is completely consistent with the traditional field construction in terms of manufacturing technology, specification and environment, without special requirements. After the pipeline module factory is prefabricated, conduct the hydraulic test.
3. Pipeline module transportation
After passing the inspection, the pipeline module leaves the factory. Since the module is loose and easy to be damaged, it is required to make professional fixed support and packaging for the pipeline module.Fig.2 is an example of pipeline module packing.
To realize one basic function of the module, a lot of equipment, valves and pipe fittings need to be integrated, which will result in large volume and self-weight definitely. Therefore, in the process of hoisting, whether in the selection of lifting equipment or in the formulation of the lifting plan, the safety and protection of functional modules should be considered. Fig. 3 and Fig. 4 are examples of pipeline module hoisting.
With the wider application of modular technology, how to improve the efficiency and quality of module design has been paid more and more attention. In some project designs, by improving the efficiency of modular design, the progress of engineering construction and procurement schedule of relevant materials can be effectively improved, the potential risks in engineering construction can be eliminated, and the reliability of engineering construction can be increased.
In the design process of specific projects, different equipment and devices, as well as different plane positions, patents and changes of natural conditions will have an impact on the modular design of the pipeline system. Therefore, in the process of modular design, taking all these factors fully into account to improve the efficiency and quality of pipeline system modular design.