Construction Plan for Anti-corrosion and Insulation of Process Piping
Thread Content
I. Preparation Notes: The project to improve measures for reducing sulfur dioxide emissions at the ***** plant of Sinopec Corporation, which is under our company’s supervision, was designed by ****** Engineering Co., Ltd. The construction site is located at the ***** plant of that company; this plan has been prepared specifically for the anti-corrosion and insulation of the process pipelines in this project. II. Basis for Preparation2.1 “Technical Specifications for Corrosion Prevention of Coatings on Petrochemical Equipment and Pipelines” SH/T 3022-2011
2.2 “Surface Colors and Markings for Steel Structures of Equipment and Pipelines in Petrochemical Enterprises” SH 3043-2003
2.3 “Technical Specifications for Thermal Insulation of Petrochemical Equipment and Pipelines” SH 3010-2000
2.4 “Corrosion Grades and Rust Removal Grades of Steel Surfaces before Painting” GB 8923-88
2.5 “Visual Assessment of Surface Cleanliness before Applying Coatings – Part 3: Grades for Treating Surface Defects on Welds, Edges, and Other Areas” GB/T 8923.3-2009
2.6 “Construction Specifications for Industrial Equipment and Pipeline Insulation Projects” GB 50126-2008
2.7 “Construction and Acceptance Specifications for Pipelines Transporting Toxic and Flammable Media in Petrochemical Industries” SH 3501-2011
2.8 Design drawings and specifications from **** Engineering Co., Ltd.
III. Project Overview
3.1 Project Overview
Project name: Improvement measures for reducing sulfur dioxide emissions at the ***** plant
Owner: Sinopec Corporation, ***** Company
Supervisor: Yueyang Changling Refining & Chemical Fangyuan Construction Supervision and Consulting Co., Ltd.
Designer: **** Engineering Co., Ltd.
Constructor: ******** Construction Co., Ltd.
3.2 Main Tasks
The corrosion prevention and painting of pipelines in this project are carried out in accordance with the requirements of “Technical Specifications for Corrosion Prevention of Coatings on Petrochemical Equipment and Pipelines” (SH/T 3022-2011) and “Surface Colors and Markings for Steel Structures of Equipment and Pipelines in Petrochemical Enterprises” (SH 3043-2003). The thermal insulation work and related acceptance procedures are carried out in compliance with the “Technical Specifications for Thermal Insulation of Petrochemical Equipment and Pipelines” (SH 3010-2000). Rust removal grade ST3. For medium temperature pipelines below 120°C, apply two coats of iron red polyurethane anti-corrosion primer, followed by one coat of polyurethane anti-corrosion topcoat; the minimum dry film thickness for each coat should be 40μm. For medium pipes at temperatures above 120°C, apply two coats of zinc silicate inorganic primer, with a minimum dry film thickness of 50μm for each coat. Main Pipes Table 1 Serial Number Name Material Pipe Length (m) 1 Seamless steel pipe Φ559*1720 #2 m 2 Seamless steel pipe Φ457*1420 #2 m 3 Seamless steel pipe Φ325*6.5 20 #1 m 4 Seamless steel pipe Ф273*9.5/*6.5 20 #48 m 5 Seamless steel pipe Ф219*8/*6.5 20 #103 m 6 Seamless steel pipe Ф168*7 20 #56 m 7 Seamless steel pipe Ф27*4 20 #87 m 8 Seamless steel pipe Ф22*4 20 #28 m 9 Seamless steel pipe Ф45*5 20 #20 m Note: The above pipes are based on the material list provided by the design institute (including the tee sections specified in 13247Y Emergency-01). In total, there are 295 pipe fittings, 215 flanges, and 86 valves. IV. Construction Technical Requirements
4.1 Construction Procedures
4.1.1 Anti-corrosion construction procedure:
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4.1.2 Insulation construction procedure:
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4.2 Insulated pipelines
| No. | Pipeline No. | Fluid | Insulation Thickness | Insulation Material | Remarks |
|-----|--------------|-------|----------------------|---------------------|---------|
| 1 | D-11701-J | Sewage | 30 | Rock wool pipe shell | |
| 2 | S-11706-J | Sulfur-containing air | 60 | Rock wool pipe shell | |
| 3 | S-11707-J | Sulfur-containing air | 60 | Rock wool pipe shell | |
| 4 | S-11708-J | Sulfur-containing air | 60 | Rock wool pipe shell | |
| 5 | S-11709-J | Sulfur-containing air | 70 | Rock wool pipe shell | |
| 6 | LS-11711-H | Steam | 30 | Rock wool pipe shell | |
| 7 | LS-11731-H | Steam | 30 | Rock wool pipe shell | |
| 8 | LS-11732-H | Steam | 50 | Rock wool pipe shell | |
| 9 | LS-11733-H | Steam | 30 | Rock wool pipe shell | |
| 10 | LS-12901-H | Steam | 30 | Rock wool pipe shell | |
| 11 | MS-11710-H | Steam | 30 | Rock wool pipe shell | |
| 12 | N-12931-J | Nitrogen | 30 | Rock wool pipe shell | |
| 13 | SC-11710-P | Condensate water | 20 | Rock wool pipe shell | |
| 14 | SC-11711-P | Condensate water | 20 | Rock wool pipe shell | |
| 15 | SC-11731-P | Condensate water | 230 | Rock wool pipe shell | |
| 16 | SC-11732-H | Condensate water | 30 | Rock wool pipe shell | |
| 17 | SC-11733-P | Condensate water | 20 | Rock wool pipe shell | |
| 18 | SC-12901-P | Condensate water | 20 | Rock wool pipe shell | |
4.3 Technical briefing
Based on the drawings and documents provided in the design, it is necessary to anticipate key points and difficulties during construction. Construction managers at all levels, especially technical workers, must receive thorough technical briefings and training. Through these preparatory measures, the awareness of employees can be fundamentally improved, technical management can be effectively strengthened, and quality control can be ensured. Implement the \"Technical Specifications for Corrosion Prevention of Coatings on Petrochemical Equipment and Piping\" SH/T3022-2011, the \"Specifications for Surface Colors and Markings of Steel Structures for Equipment and Piping in Petrochemical Enterprises\" SH3043-2003, and the \"Technical Specifications for Thermal Insulation of Petrochemical Equipment and Piping\" SH3010-2000; improve management systems to ensure that the construction process is always carried out in accordance with technical operating procedures. 4.4 Preparations and requirements before construction 4.4.1 According to the process requirements, prepare the necessary tools, machinery, instruments, etc., and make arrangements for the delivery of raw materials. Organize a construction team with excellent technical skills and experienced managers to carry out the work on site. 4.4.2 The construction site must be equipped with facilities for water supply, power supply, fire protection, etc., and the roads must be unobstructed. 4.4.3 Before the construction of the insulation layer, the following conditions must be met: 4.4.3.1 The supports and fixing elements must be in place. 4.4.3.2 The supports, hangers, structural accessories, and instrument connection components have all been installed. 4.4.3.3 Remove oil and rust from the surfaces of insulated equipment and pipes. 4.4.3.4 Complete the handover procedures for pipeline installation, welding, anti-corrosion, and other related processes. 4.5 Construction technical requirements: To ensure the long-term operational life of the product, reduce heat loss, meet the technological requirements, and achieve an attractive and tidy appearance as well as good corrosion and insulation properties, the construction personnel must carry out the work in strict accordance with relevant regulations and standards, and comply with the construction requirements outlined in this plan. 4.5.1 Corrosion prevention construction: Pipe rust removal is carried out by manual or mechanical methods. The rust removal must be thorough, to the extent that a smooth metal surface is exposed, with a rust removal grade of St3. During construction, the metal surface must not be damaged or deformed; after rust removal, the surface dust should be cleaned off with a cloth. After rust removal from the pipes, an anti-corrosion primer should be applied promptly. The primer should be prepared to be slightly viscous (so that it can be applied with a brush), and it must be applied evenly. The second coat of primer should be applied after the first coat has dried. After applying two coats of primer, the metal surface should no longer be visible. Applying the topcoat should be carried out after the pressure test is successful. The temperature in the construction environment should be between 15 and 30°C, with a relative humidity not exceeding 80%. The coating mixture should be prepared properly, with an appropriate viscosity and thoroughly mixed; any crusts or other impurities must be removed before application. A trial coating should be done prior to actual application. When brushing on, the layers should intersect in both directions; each layer should be applied repeatedly until even coverage is achieved. Apply it evenly during brushing; ensure no areas are left uncoated. The number of coating layers shall comply with the design specifications, and the top coat should be applied in the direction of the medium flow. The interval between coats should follow the instructions provided for applying the coating. The surface of the coat must be smooth without any marks, with uniform color, and free from pinholes, bubbles, sagging, flaking, or damage. 4.5.2 Pipe insulation: Insulation should be carried out after anti-corrosion treatment is completed; for pipes that are to undergo pressure testing, it should be done after the pressure test is successful. The insulation material and insulation thickness must comply with the specifications in the design documents. The insulation construction method uses the bundling technique. The width of the thermal insulation joints should not exceed 5 mm; joints in the same layer should be offset from each other, while joints between upper and lower layers should be aligned. The overlap length for each section should be no less than 50 mm. The longitudinal seams of horizontal pipes should not be located within a 45° range of the pipe’s vertical centerline; these seams must be sealed tightly with aluminum tape ； 4.5.3 Insulating Protection Layer: The material for the protection layer shall meet the design requirements. The outer perimeter of the protective shell for straight pipes should be 30–50 mm longer than the outer perimeter of the insulating layer, and a rib should be formed by pressing at one end of the circumferential overlap of the shell ； The longitudinal overlaps of the protective casing for larger-diameter pipes should also have protruding ribs pressed out ； The circumferential lap dimension shall not be less than 50 mm, and the cutting of the circumferential and longitudinal seams of the metal casing at pipe elbows shall be determined according to the type of seam. The overlap between the protective cover of the elbow and that of the straight pipe section should be 50 to 70 mm, and the overlapping area must not be fixed. The circumferential seams of the protective casing for horizontal pipes should extend downward along the slope of the pipe, while the longitudinal seams should be located at an angle of 15 to 45° below the horizontal center line, with the seam openings facing downward ； The installation of the protective layer in vertical pipes should be carried out from bottom to top, with the overlaps placed on top of each other. Insulated pipes are secured using semi-circular head self-tapping screws; the spacing between these screws should be around 200 mm, with no fewer than 4 screws per joint. The observation points, inspection areas, and maintenance sites on the pipeline must be designed as detachable structures; the insulation layer of such detachable structures should preferably be of a two-part composite type. The insulation layer near the flange connection should leave a gap of the bolt length plus 25 mm on one side of the pipe. 4.6 Quality inspection: The quality inspection of pipeline anti-corrosion works is carried out in accordance with the \"Technical Specifications for Anti-corrosion Coatings of Petrochemical Equipment and Pipelines\" SH/T3022-2011; manual rust removal is required to reach St3 level. During the coating application process, the thickness of the paint film, the number of application coats, and the quality of application should be checked layer by layer ； After completion, a visual inspection is carried out; the coating should be smooth and even in color, without defects such as bubbles, peeling, missed coating areas, rust, transparency, or wrinkling. When examined under a 5 to 10x magnifying glass, it is considered qualified if there are no microholes. The coating thickness shall be measured using a magnetic thickness gauge; it is considered acceptable if the deviation is not less than 5% of the value specified in the design. For insulation work, quality inspection is carried out in accordance with the \"Technical Specifications for Insulation of Petrochemical Equipment and Piping\" SH3010-2000. For pipelines, three samples are inspected every 50 meters; if one of them fails the inspection, an additional sample is taken for re-inspection. If still half of the samples fail, the pipeline is considered unqualified. The flatness of the protective layer shall be checked using a 1m straightedge, and it must meet the following requirements: (1) The allowable deviation for the metal protective layer shall not be greater than 4 mm. The visual inspection of the protective layer shall comply with the following requirements: (1) The metal protective layer shall have no loosening, flanging, notches, warping, or obvious dents. (2) The circumferential joints of the pipe’s metal casing shall be perpendicular to the pipe axis, while the longitudinal joints shall be parallel to the pipe axis. (3) The seam direction of the metal enclosure should be consistent with the slope direction of the equipment and pipelines. (4) The ellipticity of the metal protective layer (the difference between its length and width) shall not exceed 10 mm. (5) The overlap size of the metal protective layer shall be at least 20 mm for pipes, and at least 50 mm at expansion points; in outdoor or humid environments, it shall be at least 50 mm, and at least 75 mm at expansion points ； The overlap between the metal jackets of the straight sections and elbows of high-temperature pipes with a diameter of 250 mm or more must be at least 75 mm. V. Quality Control and Quality Assurance 5.1 Quality assurance system file:///C:/Users/pc/AppData/Local/Temp/ksohtml15476/wps27.png 5.2 Quality objectives: A product qualification rate of 98% for all sub-projects upon initial inspection ； 100% project completion rate ； Customer satisfaction rate: 95% ； 100% resolution rate for customer feedback and complaints ； Satisfaction rate after treatment: 95% ； There are no major quality or safety accidents, with minor injury incidents being less than 3‰. 5.3 Quality assurance measures: Before construction, it is necessary to be familiar with and understand the technical documents, drawings, materials related to the project, as well as the mix proportions of all materials. Understand the design intent, clarify quality standards, and achieve quality pre-control. Carefully and promptly monitor weather forecasts, and fill out the “Temperature and Humidity Record Sheet” completely, in order to determine the appropriate amount of curing agent to be used and ensure construction quality. Quality inspectors carry out strict supervision of the on-site construction quality, fully leveraging their role. Implement a quality inspection system that combines self-inspection, mutual inspection, cross-inspection, and specialized inspection, in order to enforce quality management across all employees. The mixing ratios of materials used in construction are measured with precision; these ratios must be strictly adhered to, and no changes may be made without prior testing and approval. Construction areas that fail the inspection must be redone until they meet the standards, and the reasons for the failure must be analyzed, lessons learned, and responsibilities assigned. Formulate quality reward and penalty measures to hold those responsible for serious construction quality issues accountable for their financial compensation obligations. VI. Safety Construction Measures 6.1 Establish a comprehensive safety system; provide safety training for construction workers prior to their entry to the site, in order to enhance their awareness of safety and quality. 6.2 A safety officer shall be assigned at the construction site to develop a safety construction plan and implement necessary safety measures. 6.3 Whenever work is carried out at a height of two meters or more above the reference level, qualified scaffolding, hoists, ladders, protective barriers, and safety belts must be used. Conduct a thorough inspection before starting work; safety equipment must be solid and reliable, and scaffolding should be erected in accordance with requirements ； The deck boards must be fully covered; there should be no exposed boards. 6.3 Personal protective equipment must be worn when entering the site. 6.4 Safety objective: No casualties ； No major equipment damage incidents occurred ； No fire alarms or fire incidents. In addition, safe construction should follow the HSE plan for this project.