Construction plan for insulation of equipment pipelines

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Construction Plan for Replacing the Insulation Covers of All Pipes/Tanks in the Plant Area with Aluminum or Stainless Steel Materials
I. Basis for Preparation
1. “Code for Construction and Acceptance of Thermal Insulation Works for Industrial Equipment and Pipelines” GBJ126
2. “Quality Inspection and Evaluation Standards for Thermal Insulation of Industrial Equipment and Pipelines” GB50185
3. “General Rules for Thermal Insulation Techniques of Equipment and Pipelines” GB4272
4. Atlas 98R419 titled “Thermal Insulation for Pipelines and Equipment”
5. “Safety Code for Power Supply at Construction Sites” GB50194
II. Construction Preparation
1. Technical Preparation
Organize technical personnel to conduct on-site inspections, understand the design intent, and carry out technical briefings in accordance with the construction plan, relevant codes, and quality evaluation standards. Additionally, prepare a material plan as well as technical measures for each phase of the work. It should be equipped with sufficient quantities of various common drugs and medical materials for emergency use, as well as skilled workers with years of experience in chemical construction work. At least one responsible supervisor must be present during the construction, and the surrounding equipment and ground must not be damaged or contaminated. Prepare enough plastic film or colored striped fabric to cover and protect unfinished equipment, raw materials, the floor, etc. Before construction, the technical supervisor of the project team must thoroughly study and understand the client’s requirements regarding anti-corrosion and insulation procedures, as well as the relevant technical standards for chemical engineering construction. He/she should prepare work instructions and specify the technical requirements for special equipment and particular parts, distribute these to all workers, and attach labels to the equipment to ensure that the construction processes are carried out accurately and that the project progresses smoothly. Special instructions should be provided for the key construction stages related to special equipment and its various components, and training should be given for these specific processes. Special attention should be paid to preventing common quality issues that arise during construction, as well as errors resulting from habitual operating mistakes. 2. Preparation of engineering materials: Organize the material staff to make detailed arrangements for the plan to purchase insulation materials. Before the construction begins, the design drawings and materials related to the project should be transported to the construction site and stored there in a categorized manner. Hang up identification tags for easy identification. After the insulation materials arrive at the warehouse, a second random inspection should be conducted; if they fail to meet the standards, they should be returned promptly. The main contents of the sampling inspection preparation are: 2.1 Whether the types and quantities of thermal insulation materials correspond to those indicated on the labels ； 2.2 Has the insulation material been exposed to rainwater? Does it contain standing water? ； 2.3 Whether the quality indicators of thermal insulation materials, such as thermal conductivity and bulk density, are satisfactory. 3. Labor preparation and personnel mobilization: Given the characteristics of this project, our company will assign professional construction teams and workgroups with strong technical capabilities and high professional standards to carry out the work. These personnel will be mobilized in a timely manner and placed under the unified command of the project management team to coordinate construction activities, accelerate the progress, improve the quality of work, and ensure uninterrupted construction. Job type and number of workers: Insulation workers – 2; Tinplate workers – 10; Assistants – 4. All construction teams arriving on site are first given training in areas such as labor discipline, laws and regulations, and safe technical procedures. Ensure civilized construction and compliance with rules and regulations. 4. Preparation of safety and technical documents 4.1 Provide necessary technical and safety training to the personnel involved in the project construction, so that they can understand the rules and regulations set by the client regarding discipline, safety, fire protection, etc.; clarify the specific safety measures required for work at heights, and conduct technical and safety tests when necessary. Those who fail these tests are not allowed to carry out the work. 4.2 For the construction of thermal insulation projects, complete construction drawings and design documents are required. The construction unit shall conduct self-review, professional review, and comprehensive joint reviews of the construction drawings, provide timely responses to any issues raised, develop construction plans and technical briefings based on the project conditions, and maintain written records of all this information. 4.3 Prepare the start-up report for this project, submit it, as well as intermediate inspection reports, construction records, records of concealed works, and quality inspection forms; simultaneously develop a construction plan for this project. 5. On-site Organization and Preparation 5.1 Establishment of Management Structure: This project will be carried out using the project management approach, with a rational, efficient, and capable project management team established to fully fulfill the contractual obligations. This team will undertake the five key functions of organizing, directing, managing, coordinating, and controlling the construction process. It will also handle coordination among internal and external parties as well as among different team members, ensuring that all functional aspects are utilized effectively. The team is responsible for meeting the needs related to on-site preparation, work planning, production scheduling, technical management, quality control, safe construction, engineering surveys, labor management, material supply, equipment utilization, cost accounting, testing, daily operations, and maintaining civilized construction standards. It is fully accountable for the project’s quality, safety, timely completion, costs, and service standards, ensuring that all management objectives are achieved. The project team is composed of experienced, customer-friendly, responsible, and hardworking engineering and technical personnel as well as management staff. The construction layer is carried out by a professional team with high qualifications and experience in similar projects, selected by the project management department of our unit. 6. Preparation of mechanical equipment: Prepare the construction machinery suitable for this project; it must arrive at the construction site before work begins, and power supply arrangements as well as equipment installation and testing must be carried out. Prepare sufficient spare parts for construction equipment, and all mechanical devices should be maintained and serviced in a timely manner. Construction Machinery Equipment Table Name Quantity Arrival Plan Remarks Starter machine: 2 All construction machinery and equipment shall arrive at the construction site 3 days before work begins. Rolling machine: 2 Reinforcing bar pressing machine: 2 Combined corner jointing machine: 2 III. Construction Plan 1. Construction techniques 1.1 Pipe insulation: Remove the original protective insulation layer – intermediate inspection – install rock wool pipe sleeves of 50 mm thickness – intermediate inspection – install 0.5 mm thick galvanized iron sheets – final acceptance ； 1.2 For the thermal insulation of tracing pipelines, bind them securely with galvanized iron wire at intervals of 1000–1500 mm. No requirement for local overheating; the main pipe and the heat tracing pipe can be tied together directly ； To meet the requirement of preventing local overheating, an asbestos wall must be installed between the main pipe and the heat tracing pipe. 1.3 The circumferential joints of the metal protective layer on horizontal pipelines shall follow the slope direction of the pipeline. Its longitudinal seams shall be located 15 below the horizontal center line. ～45. Place it with the seam facing down. When there are obstacles on the side or bottom, the longitudinal joint may be placed within 600 above the horizontal centerline of the pipeline. In straight pipe sections, the longitudinal seams of each section are generally connected in a straight line. 1.4 The circumferential joints of the pipeline’s metal protective layer shall be bulged and overlapped, with the overlap dimension not being less than 50 mm. For longitudinal seams, apart from the fact that a moisture-proof layer structure should not be fixed with screws, it is important that they be properly sealed and have a neat and attractive appearance. When secured with screws, the spacing between them is approximately 200 mm. 1.5 The metal protective layer on the equipment and vertical piping shall be fixed in sections to the supports. Within the same section, the connections of the protective layers should alternate between fixed and plug-in structures. 1.6 The metal protective layer on the equipment heads and pipeline elbows shall be cut into sections according to their shape and size. 2. Technical requirements for insulation installation 2.1 When installing the first layer of insulation boards, the joints between them should be staggered; the gap width must not exceed 5 mm. If the gap is larger than 5 mm, soft granular materials with similar insulating properties should be used to fill it. 2.2 The insulation layer shall be laid tightly at the areas where it meets the reinforcement plates. 2.3 The second layer of insulation material should be offset from the first layer in the same layer, with the layers overlapped; the overlap length should not be less than 50 mm. 3. Installation of the metal outer cover 3.1 Straight pipes (1) Determining the cutting length: Use a steel tape measure or iron strip to measure several points on the outside of the insulated pipe; by adding 45 mm for the seam size (overlap), the appropriate cutting length can be determined. (2) Machined joint: Form the joint on a manual folding machine (12 mm at the larger end, 15 mm at the smaller end), and mark the larger end. (3) Rolling into a circle: Place the plate with the finished seam on a rolling machine whose circumference has been pre-set, and be careful not to roll it into a circle that is too small in diameter. (4) Cylindrical rib formation: Use a manual or electric ribbing machine to create protruding ribs on the round wire; the processing should be carried out at the end with a diameter of 12 mm. The diameter of the round wire is approximately as follows, based on the outer diameter of the insulation layer: (5) On-site installation: Attach the metal protective layer tightly to the outside of the pipe’s insulation layer, overlap the seams on both sides, drill holes using a cordless drill, and fix them with rivets; the spacing between rivets should be around 200 mm. For metal protective layers with a larger outer diameter of the insulation layer, it is also necessary to create protruding ribs along the axial direction, in which case the spacing between rivets can be 250 mm. The drill bit diameter is Φ5.1mm; punching or other methods of creating holes are prohibited. Joints should be tight, smooth, and located in concealed areas. The circumferential overlap is generally 50 mm; for large-diameter high-temperature steam pipes and outdoor pipelines, it is 75–100 mm. The circumferential overlap should follow the slope of the pipeline, meaning that the overlapping joint should be oriented downward. (6) The metal cover at the end of the straight pipe near the flange, which serves to protect the insulation material, should be shaped into a serrated pattern using saw-type pliers. The outer diameter of the insulation is large, and the spacing between the serrations is also large; otherwise, it is smaller. 3.2 Elbows (1) For the metal protective layer of elbows, the cutting length is determined by adding 45 mm for the seam to the outer circumference of the insulation; the overlap with straight pipes should be at least 100 mm. The processing and installation methods are the same as those for straight pipes. (2) For the metal protective layer of dried shrimps, the detail drawing can be developed using the parallel line method or calculations can be carried out to determine the required material amounts; alternatively, the length of the material to be used can be set as the outer circumference of the insulation structure plus 100 mm, while the width should be 1/12 of the outer circumference. The material should then be cut into strips, taking into account the necessary overlapping dimensions. For the metal protective layer at the bends of high-temperature pipes, a full lap joint style can also be used, allowing the lap length to range from 15 to 250 mm; without the need for rivets, this enables the metal protective layer at the bends to expand freely. 3.3 For tees, the processing and installation method is the same as that for straight pipes; the metal protective layers of the branch pipe and the straight pipe are fixed using rivets. 3.4 Precautions for processing and installation (1) It is not permitted to use metal protective layers with obvious defects, such as wrinkles, cracks, deep scratches, and signs of corrosion. Immediately after the insulation layer is installed, the metal protective layer is put in place to avoid having to set up scaffolding again. (2) The cutting of the metal protective layer should be precise, with reasonable trimming to minimize stray scraps and edges. (3) The processed metal protective layers should be stacked neatly and numbered for easy retrieval. 4. Inspection of anti-corrosion layer, insulation layer, and protective layer 4.1 Visual inspection: The coating should be smooth and even in color, with no pinholes, bubbles, or peeling defects. Under examination with a 5-10x magnifying glass, those without micropores are considered qualified. 4.2 Coating thickness inspection: Magnetic (or ultrasonic) thickness gauges are used for measurement; the coating thickness should be uniform, and both the thickness and the number of layers must meet the design specifications. The specific requirements are as follows: (1) Use a magnetic thickness gauge for thickness measurement; the reading for a single point is obtained as the average of the readings from three adjacent points. (2) Take 5 points evenly distributed at the upper, middle, and lower parts of the block as inspection points, and make proper records. (3) The dry film thickness of the coating shall not be lower than nor higher than the specified value, with an allowable deviation of ±5%. 4.3 Coating adhesion inspection: The coating adhesion is inspected using the cross-hatching method. 4.4 Check whether the insulation fasteners and supports are installed correctly and securely; the supports must not protrude outside the insulation layer. 5. Check whether the insulation method and thickness of the insulation layer meet the design requirements. The thickness of the insulation layer can be checked using a pin-type thickness gauge or a steel probe. During inspection, a steel probe is inserted vertically until it reaches the wall of the equipment or pipeline, after which a steel ruler is used to measure the thickness; the reading accuracy must be within ±1 mm. 6. For quality inspection, sampling points are as follows: three samples should be taken every 30 m2 of equipment, and one sample per 20 m of pipeline. If one of the test points fails, an additional test point should be taken nearby for reinspection; if still 1/2 fail, that location should be deemed failed. 7. The visual inspection of the protective layer shall comply with the following requirements: (1) The circumferential joints and longitudinal joints of the galvanized iron sheets used for pipe installation shall be perpendicular to each other and form straight lines. (2) The direction of the seams in the installation of galvanized iron sheet for pipes should be consistent with the slope direction of the pipes. (3) The overlap dimension of the metal protective layer shall meet the design requirements. (4) It is strictly prohibited to step on or stack items on the installed metal enclosure. For areas prone to inevitable trampling, temporary protective measures should be taken. IV. Technical measures to ensure quality 1. Thoroughly implement and uphold the philosophy of putting quality first. 2. Strictly implement quality standards and technical requirements, ensuring that all personnel involved in the construction carry out their duties and take responsibility for quality control. 3. The records of demolition and construction/installation must be filled out carefully, ensuring they are truthful, reliable, and completely accurate. 4. The procedures for handing over work processes must be clear, and critical parts should be inspected together with the quality control department. 5. Focus on the technical training related to the construction of new equipment and new processes, and ensure that the necessary construction tools are available. 6. Strengthen the management of raw materials; substandard products must not be used in projects. 7. Establish a quality assurance system at the construction site; quality inspections shall be carried out by designated personnel who work in conjunction with the supervision engineer to ensure the quality of the project. 8. Carry out construction strictly in accordance with the prescribed procedures, rigorously follow the established rules and standards, and strive to create high-quality projects. 9. Materials shall be stored in piles, classified by specifications and batch numbers. 10. Strictly implement a three-level self-inspection system at the department, team, and group levels in accordance with standards. 11. Ensure quality control at each stage of the process; assign specific personnel to tasks, keep records, and enforce strict rewards and penalties. 12. Construction must be carried out strictly in accordance with **standards and the instructions; no one is allowed to lower these standards without the approval of the technical and inspection departments. 13. Carry out meticulous construction to eliminate common problems; not only must all requirements be met, but effort also needs to be put into the overall aesthetic quality of the project. V. Technical measures to ensure safety 1. Implement a three-level safety management system, establishing a safety management framework led by the project manager. 2. Key areas of prevention: 2.1 Falls from heights of more than 2 meters; 2.2 Electric shock accidents; 2.3 Accidents caused by objects hitting people; 2.4 Injuries resulting from equipment and tools; 2.5 Robust and flaw-free systems; 2.6 Accurate inspections; 2.7 Equipment that is free from faults; 2.8 Personnel who do not violate regulations. 3. Safety measures: 3.1 Workers at the construction site must strictly adhere to the requirements regarding safe production and civilized construction, actively implement standardized management at the site, and organize construction in a scientific manner in accordance with the construction plan. 3.2 All personnel at the construction site must strictly comply with the \"Safety Technical Regulations for Building Installation Projects\" and the \"Safety Technical Operating Procedures for Building Installation Projects\". 3.3 The installation and use of temporary electrical circuits and facilities at the construction site must comply with the requirements of the \"Technical Specifications for Safety in Temporary Electrical Use at Construction Sites\" JGJ46-88 issued by the Ministry of Construction. Electrical circuits must be installed in accordance with the temporary electrical construction plan; it is strictly prohibited to connect power supplies by pulling wires arbitrarily. 3.3.1 Leakage protectors must be installed in the power distribution system. It shall comply with the GB6829-86 standard ； 3.3.2 The safety devices of electric machinery and hand-held electric tools shall comply with **relevant standards and safety technical regulations; in addition to proper protective grounding, leakage protectors shall be installed as required. 3.3.3 Protective measures must be installed at the construction site, in compliance with the requirements of JGJ80-91 \"Technical Code for Safety in High-Height Work in Building Construction\". In accordance with GB3608-83 “Classification Standards for Working at Heights”, a three-level management system is implemented: (1) A height range of 2–5 meters falls under Level 1 management, which is the responsibility of a professional foreman ； (2) 5–15m falls under secondary management, which is the responsibility of the construction supervisor ； (3) For heights over 15m, it falls under level 3 management, which is the responsibility of the project manager ； (4) The construction supervisor is responsible for the safety techniques related to work at heights on this project. The safety protection measures should be inspected and approved by the person in charge. When it is necessary to temporarily remove or modify these safety facilities for work purposes, approval from the construction supervisor must be obtained, and appropriate reliable measures must be taken. (5) When different types of work are carried out in vertical overlap, operations must not be conducted in the same vertical direction. (6) The erection of scaffolding must comply with the provisions of safety technical regulations. It can only be put into use after passing inspection by the relevant technical personnel. When dismantling the scaffold, there must be no other people below. (7) When performing work at heights in rainy or snowy weather, reliable anti-slip, heat preservation, and anti-freezing measures must be taken. 3.4 Special operation personnel on site must receive specialized training in accordance with GB5036 \"Regulations on the Safety Technical Assessment and Management of Special Operation Personnel\", and only after passing the assessment may they work with a valid certificate. 3.5 Safety inspections and assessments are conducted once a month, in accordance with the requirements of the Ministry of Construction’s JGJ59 \"Safety Inspection Scoring Standard for Building Construction\". 3.6 Construction workers shall use personal protective equipment properly; they must wear safety helmets when entering the construction site, and safety belts must be worn when working at heights. Strictly enforce operating procedures and rules and regulations at the construction site; unauthorized commands and violations of regulations are prohibited. 3.7 Strictly implement the Fire Protection Regulations of the People’s Republic of China; establish fire prevention responsibility systems and volunteer fire brigades; install fire protection facilities that meet fire safety requirements; and ensure they are kept in good condition and readily available. 3.8 Establish a comprehensive safety assurance system, organize employees to study relevant safety laws and operating procedures carefully, formulate safety measures, set up a safety leadership team, assign full-time safety officers, and conduct regular inspections and training to eliminate all potential safety hazards at an early stage. 3.9 Before the commencement of any sub-project, a stringent safety briefing must be conducted. Regular and irregular safety inspections should be carried out at all construction sites, with any issues identified being addressed promptly. 3.10 Install safety warning signs at the work site, and set up prohibition signs in key construction areas to prevent accidents. 3.11 Assign 1-2 full-time safety officers to the site to conduct regular inspections on a daily basis; the focus of these inspections is: 3.11.1 Whether safety helmets, safety belts, and safety nets are being used correctly. 3.11.2 Are safety signs and warning signs installed as required? 3.11.3 The temporary power supply must have a reliable grounding protection, with the grounding resistance being less than 4Ω. 3.11.4 Whether the use and storage of flammable and explosive equipment and items are carried out in accordance with regulations. 3.11.5 The inclination angle of the ladder used for working at heights relative to the ground should be between 60° and 70°; the A-frame ladder must be equipped with safety switches, and anti-slip measures should be in place at its base. 3.11.6 Whether the scaffold is erected in accordance with the operating procedures, and whether protective nets are installed. 3.12 When working on scaffolds or hoists at a height of more than 2 meters, safety helmets and safety belts must be worn. Persons with health issues such as high or low blood pressure, weak vision, deafness, or flat feet are strictly prohibited from working at heights. VI. Technical measures to ensure the project timeline and schedule for progress 1. Construction preparation 1.1 Sign the construction contract and other relevant documents within the specified time frame. 1.2 During the contract signing period, the construction materials and machinery shall be prepared, and they shall be brought to site for debugging, in order to meet the construction requirements with high standards. 1.3 Conduct pre-job technical and safety training for personnel before commencement, help them become familiar with the construction requirements and procedures, and formulate a construction plan. 1.4 Conduct acceptance inspections on the raw materials upon their arrival, issue reports thereon, and address any technical quality issues in a timely manner in collaboration with relevant units and departments. 1.5 Develop a construction flowchart. 1.6 Demarcate the construction area and carry out work with a license. 2. Construction coordination 2.1 Carry out zone-based work in accordance with the construction schedule and flowchart to avoid waste of productivity. 2.2 Construction work shall be carried out from top to bottom, starting with the more difficult tasks first. 2.3 If insulation work overlaps with the manufacturer’s production, the manufacturer’s production shall take precedence. 2.4 Foundation cleaning: After each section is completed, it should be promptly inspected and accepted, and a quality report should be issued. Once the inspection shows satisfactory quality, the next stage of construction can proceed. 2.5 When the power supply, lighting, and safety measures for construction meet the requirements, overtime work should be carried out to catch up on progress and improve productivity. 2.6 When construction is halted due to factors beyond human control, it is necessary to catch up on the project progress in accordance with the construction schedule and flowchart, so as to keep it in line with the planned timeline. 2.7 The construction worker shall submit a material plan in advance to the material officer, who will then prepare the materials according to this plan. If the available materials do not meet the requirements of the construction work, it is necessary to order additional materials promptly to ensure that the schedule is maintained. 3. Mechanical Applications 3.1 Construction machinery should undergo routine safety and operational condition checks before each shift. 3.2 Construction machinery should be maintained and inspected after each shift, with any issues fixed promptly. 3.3 Construction machinery spare parts must be sufficient for replacing repair components. 3.4 Assign dedicated maintenance personnel to work alongside the construction team to promptly repair damaged machinery. 3.5 Mechanical operation must meet safety requirements. 4. Schedule for project completion: In accordance with the client’s deadline requirements, additional personnel can be assigned as needed to ensure that the project is completed by the specified date. 7. Measures for environmental protection: During construction, it is inevitable that waste, wastewater, and noise will be generated, thereby causing environmental pollution. The effectiveness of environmental protection measures at the construction site not only affects the conditions within the site itself but also has an impact on the overall environmental situation in the area. Therefore, environmental protection efforts at the construction site are part of the city’s overall environmental protection strategy, and the site must meet the requirements set for urban environmental protection. The main aspects of environmental protection at construction sites include preventing air pollution, preventing water pollution, and preventing noise pollution. 1. Waste at the construction site should be removed promptly, and water should be applied in appropriate amounts to reduce dust generation. 2. The construction site must establish a system for misting water to reduce dust, and assign dedicated personnel to carry out this task as well as to clean up loose dust promptly. 3. A dedicated material storage room should be set up at the construction site, with the floor and walls treated to be waterproof and leak-proof. 4. It is prohibited to bury toxic and harmful waste underground to prevent contamination of groundwater and the environment. 5. The construction site shall establish corresponding noise reduction systems and measures in accordance with the \"Limits on Noise at Construction Sites\" (GB12523-90). 6. Strengthen the management at the construction site, and in particular prevent noises such as intentional knocking, screaming, and rough handling during loading and unloading, in order to minimize noise disturbances to the local residents. 7. After each shift’s work is completed, clean up any residues left at the site and on the machinery, and transport them to the designated location. 8. After the project is completed, thoroughly clean the site to restore it to its original state, meeting the acceptance standards set by the client.