Process Pipeline Construction Plan 1

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Process Pipeline Construction Plan 1. Project Overview and Characteristics 1.1 Overview: In Area A of this project, the length of process pipelines is approximately 22,500 meters. The pipe diameters range from DN25 to DN1400, and the materials used include carbon steel (20#, 16Mn), galvanized pipes, stainless steel pipes (316, UB6), rubber-lined steel pipes, fabric-reinforced rubber pipes, glass fiber reinforced plastic pipes, as well as air ducts fabricated on-site. The actual quantities required for the project are shown in Table 1. Table 1: List of Major Engineering Components (Unit: M)
Serial No. | Component Name | Material |
1 | 16Mn20# Zinc-Coated Steel Pipe | 16Mn20# Zinc-Coated Steel |
2 | 316L UB6 Steel Lined Pipe | 316L UB6 Steel |
3 | Glued Pipe Fittings | — |
4 | Cloth-Lined Air Pipe | — |
Subtotal | — | — | 10,10 |

Outer Pipe | 49,007 | 8,853 | 24,030 | 30,000 | 1,682 | 5,287 |
Finished Product Packaging | 353 | 353 | 3,870 |

DAP Powder Pipeline | 543.8 | 6,021 | 114,58 | 4,870 |
Process-related Components | 30,137 | 689 | 141,118 | 108,0 | 3,574 | 5,982 |

Integrated Tank Area | 310 | 163 | 20 | 493 | 6,877–878 | 100 | 100 | 7 |
Total | 5,783.89 | 6,143 | 340 | 399 | 214,118 | 115,060 | 2 |

Grand Total | 24,740.8 | 1.2 |

**Engineering Characteristics**
The pipes in this installation are mainly located within a 29M-high framework with 6 layers; the pipe layout is compact, making it difficult to carry out cross-work between different framework layers. The media used are highly corrosive, so high standards are required for pipe sealing. There are various types of materials involved, and welding 316L and UB6 steel presents challenges due to the high quality requirements. Therefore, careful planning and meticulous construction are necessary, along with the use of advanced construction techniques and methods to ensure timely completion and high quality.

**Basis for Preparation**
1. This plan was prepared based on the tender drawings, tender documents, and the following specifications. 2.2 The procedures and specifications to be followed for the construction of the process pipelines of the equipment are shown in Table 4 below. Appendix 4: Regulations and Standards to be Applied
Serial Number | Name | Code Number
1 | Code for Construction and Acceptance of Industrial Metal Piping Systems | GB50235--97
2 | Code for Construction and Acceptance of On-site Welding of Industrial Piping Systems | GB50236--98
3 | Radiographic Inspection and Quality Classification for Butt Welds in Steel Fusion Welding | GB3323--87

3. Main Construction Procedures
- Material acceptance upon delivery
- Prefabrication in the piping factory; pressure testing after cutting, then transportation to the site
- Piping installation; non-destructive testing to ensure that the joints are sound
- Construction preparation
- Pressure testing of the piping system
- Purging of the piping system
- Individual unit testing
- Integrated system testing

4. Construction Preparation
4.1 Technical Training
To ensure the progress and quality of the construction of the process piping systems in this facility, as well as to facilitate smooth construction, training sessions on process piping are held before the project begins. All construction personnel are trained on the drawings, regulations, and standards, and are informed about the process flow, construction organization plans, construction methods, as well as the technical characteristics and challenges associated with the construction. To ensure that all personnel involved in the construction have a good understanding of the overall construction procedures, layout, process flow, and structure of the project; to enable them to grasp the key points and difficulties during construction as well as the quality control requirements for critical processes; and to introduce advanced construction techniques and methods in this facility. Welders shall receive training and testing specific to the materials used in this project; all welders must hold valid certificates to work. A group of skilled welders will be trained for welding the special materials used in this project. Through learning and training, the theoretical knowledge, practical skills, as well as awareness of quality and safety among the construction workers will be improved, so as to ensure the high-quality and efficient completion of the installation work. 4.2 Preparation of technical documents: Before construction, technical personnel are organized to study the regulations, standards, and drawings. A detailed construction plan for the process pipelines of the installation is prepared and communicated to the work teams. Single-line diagrams are drawn, welding process evaluations and tests are conducted, and welding procedure specifications are established. A sufficient number of qualified welders with the appropriate certifications for working on the process pipelines of this installation are assigned, and it is ensured that the information on their certificates matches the welding locations and that the certificates are still valid. Based on the overall construction schedule, a network plan for the construction of process pipelines is prepared, along with plans for construction equipment and the deployment of labor force. A schedule for construction materials is also developed to facilitate material procurement and construction in accordance with the layout drawings. 4.3 Location of the pipe processing plant: The pipeline work for this installation employs advanced industrialized construction methods – components are prefabricated in a pipe processing plant, where mechanical assembly lines are used for production. The complete process involves using various types of specialized machinery in the plant to fabricate different kinds of components, inspecting and repairing valves, cutting pipes and fittings according to the layout drawings, preparing prefabricated bevels, assembling them into pipeline units, and conducting tests. Once they pass the tests, the ends of the pipes are sealed before they are transported to the site for final assembly. The prefabrication depth at the pipe processing plant is 40%–50%, with a processing capacity of 1,000 tons per year. Workshop 877# or 878# on site is utilized as a temporary pipe processing plant; the specific layout is shown in Figure 1, while the equipment available in the plant is listed in Table 2. 4.4 Site preparation: In accordance with the requirements of the process pipeline construction plan, a construction team for process pipelines shall be arranged at the site. Temporary sheds for welding machines and gas welding tools, as well as temporary warehouses and material storage areas, shall be set up. A secondary electrode warehouse shall be established on-site, equipped with electrode drying ovens, thermostats, dehumidifiers, ventilators, wet and dry thermometers, and electrode racks. All measuring instruments must have calibration labels, be properly calibrated, and be within their valid expiration dates. Establish a comprehensive management system for the baking and distribution of welding electrodes in accordance with the company’s Q/SHF standards. The roads for the crane to enter and leave the site are unobstructed, and the temporary water and electricity needed for construction are supplied to the points where they are used. Table of Construction Equipment and Tools
Serial Number | Name | Specification | Quantity | Unit | Remarks
1 | Truck Crane | 50 t | 1 | unit |
2 | Truck Crane | 25 t | 1 | unit |
3 | Transport Truck | 8 t | 1 | unit |
4 | Electric Bottle Cart | 5 t | 1 | unit |
5 | Equilibrium Ion Cutter | LGK---100 | 1 | unit |
6 | Tungsten Inert Gas Welding Machine | WSA4---300 | 8 | units |
7 | Silicon Rectifier Welding Machine | GS---400SS/12KW | 16 | units |
8 | Beveling Machine | GPJ---35 | 1 | unit |
9 | Semi-automatic Cutting Machine | GT—100A | 2 | units |
10 | Grinding Wheel Cutter | Disk φ300 | 4 | units |
11 | Bench-type Grinding Wheel Machine | φ100 | 2 | units |
12 | Pressure Testing Pump | SY---600 | 1 | unit |
13 | Bench-type Drilling Machine | φ25 | 1 | unit |
14 | Swing-arm Drilling Machine | φ50 | 1 | unit |
15 | Outer Heat Treatment Oven | 300---500℃ | 1 | unit |
16 | Constant Temperature Box | 100---200℃ | 1 | unit |
17 | Dehumidifier | 1 | unit |
18 | Wire Stripping Cutter | Z3T---R4 | 2 | units |
19 | Electric Polishing Machine | φ100---φ125 | 24 | units |
20 | Microscope | TX2505---3005 | 2 | units |

Floor Plan of 10,000 T/year Pipe Processing Plant
Plasma Cutting Machine Shed | Tungsten Inert Gas Welding Machine Shed | Stainless Steel Alignment Wooden Platform | Stainless Steel Material Storage Area | Gate for Pressure Testing, Inspection, and Repair | Pressure Testing Pump | Finished Goods Warehouse | Electric Vehicle | Carbon Steel Pipe Alignment Steel Platform | Fiberglass Pipe Alignment Wooden Platform | Welding Machine Shed | Tungsten Inert Gas Welding Machine Shed | Carbon Steel Material Storage Area | Fiberglass Material Storage Area | Gas Welding Tool Shed | Grinding Wheel Cutter | Grinding Wheel Cutter | Grinding Wheel Machine | Swing-arm Drilling Machine | Bench-type Drilling Machine | Office | Living Quarters | Finished Goods Warehouse | Forklift | Main Gate | Main Gate | Carbon Steel Beveling Machine | Electric Hoist | Stainless Steel Beveling Machine | Fire Fighting Equipment | Fire Fighting Equipment | Fire Fighting Equipment | Fire Fighting Equipment

70000
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5. Main Construction Methods
5.1 Material Acceptance
5.1.1 All pipes and pipe fittings shall come with quality certificates from the manufacturer, and shall meet the requirements specified in the design documents. The quality certificate for steel pipes shall include the contract number, the name or logo of the supplier, the product standard number, the steel grade, the furnace/large tank number, batch number, weight and quantity, as well as the name, specification, quality grade of the product, along with the stamp of the technical supervision department. 5.1.2 For large-diameter steel pipes, it shall be checked that each pipe end is marked; the markings shall include the steel grade, product specifications, product standard number, supplier’s mark, and registered trademark, all of which must be present. For alloy steel pipes, the furnace number and batch number shall be indicated after the steel grade. 5.1.3 For small-diameter steel pipes supplied in bundles, their labels should indicate the supplier’s mark or registered trademark, the grade of the steel, furnace number, batch number, contract number, product specifications, standard number, weight, number of pipes, date of manufacture, and the mark of the supplier’s quality control department; all these details must be present. 5.1.4 Welded steel pipes or galvanized steel pipes may not have any marks, but they should still have labels, with the same information as mentioned above. 5.1.5 Alloy steel pipes shall undergo optical pyroanalysis in accordance with the specified requirements, to ensure that their chemical composition meets the provisions of the design and contract. 5.1.6 For stainless steel pipes and fittings for which intergranular corrosion tests are required as per the design specifications, it is necessary to check that the results of these intergranular corrosion tests indicated in the manufacturing quality certificate meet the design requirements. If no such information is provided, supplementary tests shall be carried out in accordance with the relevant provisions in the \"Method for Testing Corrosion of Stainless Steels GB4334.1-9\" during inspection. 5.1.7 All pipes and fittings shall undergo a visual inspection; their surfaces must be free from defects such as cracks, scars, pitting, inclusions, wrinkles, double coating, scratches, and severe rust. Fiberglass reinforced plastic composite pipes must not have any signs of crushing, breaking, or chipping. 5.1.8 For steel-lined rubber hoses, the electric spark method shall be used to check that the rubber lining inside the steel tube is intact; the surface should be smooth and soft without wrinkles, and there should be no cracks, pits, bubbles, or other defects with a depth of more than 0.5 mm. 5.1.9 Pipes of various materials and specifications shall be inspected in accordance with the relevant specifications; the diameter, wall thickness, degree of bending, etc. shall all meet the requirements specified in the material standards. 5.1.10 All valves shall undergo a visual inspection, and the inspection items include: a. The valve’s model specifications, nameplate, serial number, pressure rating, and material designation must meet the requirements specified in the drawings. b. The external and visible surfaces, as well as the threads and sealing surfaces, must be free from any damage or rust. Cast valve bodies must be free from harmful defects such as sand holes, shrinkage cavities, pores, and cracks. c. Upon arrival of the valves at the site, strength tests and tightness tests should be conducted on a sample basis, in proportion to those from the same manufacturer, of the same specifications, and of the same model. 5.2 Storage of Materials 5.2.1 Due to the differences in the materials used for the process pipelines in this project, carbon steel pipes, galvanized pipes, stainless steel pipes, fiberglass pipes, and steel-lined rubber pipes must be stored in separate storage areas; mixing them is strictly prohibited. Carbon steel pipes can be stored outdoors, but they need to be placed on leveled planks and covered with tarpaulins. Stainless steel pipes should be stored on wooden planks. All valves must have their ends checked to ensure they are properly sealed, while small pipe fittings and valves should be kept on shelves. 5.2.2 The storage location for glass fiber reinforced plastic pipes and steel-lined rubber pipes should be free from sunlight and heat sources, with an indoor temperature within the range of 5–40°C. When handling and stacking, handle with care to avoid severe vibrations or collisions. 5.2.3 All stored materials must be clearly labeled, indicating specifications, material type, certificate number, quantity, and other relevant information. 5.3 Storage of welding materials 5.3.1 A secondary storage area for electrodes should be established on-site, under the supervision of a dedicated person. The storage area should be equipped with high-performance dehumidifiers, ventilators, dry (wet) thermometers, as well as equipment for drying electrodes. It should also have product qualification certificates and calibration certificates displayed there. 5.3.2 Welding electrodes shall be classified strictly in accordance with specification requirements, arranged neatly by specification, and labeled. 5.3.3 A complete system for the storage and distribution of welding electrodes should be established in the welding electrode warehouse. 5.4 Prefabrication of pipes in the factory 5.4.1 Before the pipes are installed, it is necessary to complete the drawing of the single-line diagrams. Once the equipment is in place, the single-line diagrams are drawn for each pipe according to the construction drawings, indicating the route, elevation, coordinates, specifications, length, angle, slope of each pipe, as well as the location of accessories and supports. The starting and ending points of the pipes, along with the names and locations of the associated equipment, are also indicated. It is also necessary to map out the locations of the instrument interfaces and the additional pipe connections for system purging. 5.4.2 All pipes shall be prefabricated in the processing plant to a degree of about 50% completion; all pipes are cut according to the single-line diagram, and steel grade transfer must be carried out. Pipes of various materials are prefabricated separately, and markings should be made once prefabrication is complete. The prefabrication process for pipeline processing is shown in Figure 2. 5.4.3 Cutting 5.4.3.1 Carbon steel pipes can be cut using an oxy-acetylene flame or mechanically (with a grinder). Galvanized pipes are cut using mechanical methods. Stainless steel pipes are cut using plasma or mechanical methods; when cutting or grinding them with a grinder, special grinding wheels must be used. 5.4.3.2 The groove after cutting must be smooth, and its surface should be cleaned thoroughly. Carbon steel pipes are cleaned using files and grinding machines, while stainless steel pipes are cleaned with specialized angle grinders. Tools for processing stainless steel pipes and carbon steel pipes should not be used interchangeably. 5.4.3.3 When welding pipes and fittings with the same wall thickness, their inner walls must be aligned, and the misalignment of the inner walls shall comply with the specifications. 5.4.4 Prefabrication 5.4.4.1 During the pipeline prefabrication process, site conditions must be taken fully into account; the prefabrication depth and the location of the joints should be determined in accordance with the principles of facilitating transportation and installation. A margin of 50–100 mm should be left at the joints for adjustments during installation. When prefabricating the openings for the primary components of instruments, processing should be carried out simultaneously according to the drawings. 5.4.4.2 Pipeline components shall be selected in accordance with the quantity, specifications, and materials specified in the single-line diagram, and the pipeline system number shall be indicated in the diagram, along with the sequence numbers of each component according to their prefabrication order. 5.4.4.3 The welding, non-destructive testing, machining, assembly, and inspection of pipeline components shall comply with the relevant provisions of the specifications. 5.4.4.4 The prefabricated pipe sections shall have sufficient rigidity and may be reinforced if necessary to ensure that no deformation occurs during storage and transportation. 5.4.4.5 For the prefabricated pipe sections, the interior should be cleaned thoroughly, the pipe ends should be sealed in a timely manner, and the inside of the pipes should be kept clean. 5.4.5 Pipe Welding 5.4.5.1 Selection of welding methods: For carbon steel pipes, when the diameter is relatively large, manual arc welding can be used; after cleaning the inner surface, a root weld is applied ； For carbon steel pipes with relatively small diameters, argon-electric welding is used ； Galvanized pipes are connected by threading ； Stainless steel pipes are welded using TIG welding, with argon gas filled inside for protection ； Glass fiber pipes are manufactured using methods such as bonding in accordance with design requirements. 5.4.5.2 Selection of welding materials: 20#. For TIG welding, H08Mn2SiA wire is used, while for shielded metal arc welding, E4315 (or E4303) electrodes are used ； The gas welding wire uses H08MnA.