The manufacturing process of Y-type pipeline filters is a complex multi-step procedure that encompasses material preparation, processing, assembly, inspection, and labeling. Below is a detailed introduction to each step in the process:
I. Material Preparation
Material Selection: Appropriate materials are selected based on factors such as the operating environment, medium properties, working temperature, and pressure. Commonly used materials include carbon steel, stainless steel, cast iron, copper, etc., all of which must comply with relevant standards and regulations like GB/T1220, GB/T3280, and GB/T4237.
Material Inspection: Rigorous inspections are conducted on the selected materials to ensure their quality meets the required standards.
II. Processing
Cutting: Based on production plans and drawings, materials such as stainless steel plates, perforated plates, and filter screens are cut. Stringent control of dimensional accuracy is necessary during this process to prevent material waste.
Cutting & Rolling: Plasma cutting machines are used to cut raw pipes, filter element holders, and perforated plates, ensuring smooth cuts and precise dimensions. For perforated plates, additional rolling is required to form the desired shape.
Filter Element Fabrication: The filter screens are turned over and rolled at both ends before being fitted onto appropriate square tubes. A punch plate is used to calibrate the roundness, ensuring the filter element's ovality and filtration accuracy meet the specified requirements.
III. Assembly
Assembly of Raw Pipe and Filter Element Holder: The filter element holder's locating ring is positioned at the concentric point and spot-welded securely. It is then inserted into the cut end of the raw pipe, aligning the centerline of the holder's circular hole with the bisecting lines of the raw pipe and forming a 45° angle with the centerline of the raw pipe's inner hole. A 45° template is used to verify correctness before welding.
Welding of Flange and Raw Pipe: The end of the raw pipe is thoroughly cleaned of rust. A qualified flange is placed with its working surface facing downwards on the welding platform, and an appropriate backing plate is inserted into its inner hole. Argon arc spot welding and fillet welding are then performed to ensure the quality of the welds.
Tee Assembly: All components are assembled according to the drawings, followed by welding and inspection.
IV. Inspection
Visual Inspection: The filter's surface is inspected for flatness, cracks, rust, and other defects.
Dimensional Inspection: Measuring tools are used to verify the filter's dimensions against the drawings to ensure compliance.
Pressure Testing: The filter undergoes both sealing and strength tests to assess its pressure bearing capacity and sealing performance.
Leak Testing: The filter is inspected for leaks under specified pressure conditions.
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