Key Installation Points for Ceramic Tile-Lined Pipes

The superior wear resistance of ceramic tile-lined pipes is only fully realized if the installation is performed correctly.Improper installation can lead to liner damage,premature failure,and safety hazards.The following points are critical for a successful installation.

1.Pre-Installation Handling and Storage

Handle with Care:Never drop or strike the pipes.The ceramic tiles are extremely hard but brittle and can crack or shatter upon impact.The steel shell can also be deformed,compromising the fit of the liner.

Protect the Ends:Keep protective end caps on until the moment of connection.This prevents damage to the ceramic edges and prevents foreign objects from entering the pipe.

Proper Storage:Store pipes on a flat,stable surface.Use adequate supports to prevent sagging or bending.Do not stack other heavy materials on top of them.

2.Cutting and Modification(To Be Avoided)

Pre-Planned Lengths:The golden rule is to avoid cutting ceramic-lined pipes in the field whenever possible.Cutting is a highly specialized,messy,and risky operation that can easily damage the liner.Always order pipes pre-cut to the required lengths from the manufacturer.

If Cutting is Unavoidable:If a pipe must be cut,it must be done by a trained professional using specific tools and methods.This typically involves using a cold-cutting method(e.g.,an abrasive saw with a guide)and then carefully grinding and sealing the exposed ceramic edges at the cut to prevent moisture ingress and liner delamination.The newly exposed steel end must be professionally re-beveled for welding.

3.Lifting and Positioning

Use Correct Slings:Use soft slings or nylon straps for lifting.Never use steel chains or wire ropes directly on the pipe,as they can easily scratch the steel shell and,more critically,slip and impact the ceramic liner near the ends.

Lift with Care:Lift the pipes smoothly and avoid swinging them.Ensure the load is balanced to prevent the pipe from bending.

4.Alignment and Assembly

Proper Alignment is Crucial:Misalignment is a primary cause of failure.Use proper supports,cradles,and alignment tools to ensure the pipes are correctly aligned before tightening flange bolts.Do not use force to pull misaligned pipes into position.Forcing them can create point loads that crack the ceramic tiles or damage the flange faces.

Gasket Selection:Use the gaskets specified by the system designer or pipe manufacturer.They are chosen for their compatibility with the service conditions(temperature,pressure)and the flange type.

5.Flange Bolting Procedure

Clean Flange Faces:Before assembly,ensure the flange faces and gaskets are clean and free of debris.

Use a Torque Wrench:Always use a calibrated torque wrench.

Follow the Correct Sequence:Tighten the bolts in a star or cross pattern sequence.This ensures even pressure distribution across the flange face,which is essential for creating a uniform seal without putting excessive stress on any part of the ceramic mosaic.

Torque in Stages:Do not tighten a single bolt fully at once.Instead,torque all bolts to about 30%of the final value,then to 60%,and finally to the full specified torque.This method ensures a perfect,leak-free seal.

6.Welding Considerations(Butt-Welded Systems)

For systems where pipes are butt-welded together instead of using flanges,extreme caution is required to protect the liner.

Protect the Liner from Heat:The intense heat from welding can damage the ceramic tiles and the adhesive bonding them near the weld zone.It can cause tiles to crack or the adhesive to burn,leading to liner failure.

Use Heat-Sink Compounds:Apply specialized heat-sink paste or use heat-absorbing materials to the internal liner on both sides of the weld joint.This helps draw heat away from the liner.

Limit Heat Input:Welders must use controlled techniques to minimize heat input into the pipe.

7.Supporting the Pipeline

Adequate and Correct Supports:The completed pipeline must be properly supported according to the design drawings.Supports must prevent any sagging or undue stress on the pipes and flanges.

Avoid Point Loads:Ensure that pipe clamps or supports do not create point loads that could distort the steel shell and crack the ceramic lining inside.

Summary:

The successful installation of ceramic tile-lined pipes hinges on respecting the fragility of the liner.The core principles are careful handling,precise alignment,controlled bolting,and avoiding field modifications.Rushing the installation or using methods suitable for plain steel pipe will compromise the system's integrity and negate the benefits of the wear-resistant lining.Always refer to and follow the manufacturer's specific installation guidelines.