Overall prefabrication of the process system
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In the current process system renovation stations, there is a requirement for class 1 hot work. To reduce the need for such hot work, it is planned to pre-fabricate the components outside the station at a 1:1 scale; after prefabrication, they are disassembled at the flanges and transported into the station for secondary installation. This involves aspects related to the positioning of supports in terms of civil engineering work. I would appreciate it if everyone could provide some information on how to position and manufacture the valve supports outside the station. Thank you very much!
This is a new problem that has arisen as a result of the improved capacity for prefabrication in pipeline factories; strangely, wasn’t there any corresponding structural diagram provided in the design? If prefabricated pipe sections are not used and instead on-site prefabrication and installation is adopted, would support pillars, brackets, and holders then not be necessary?
Reply to 2# WiseOne: The design provides only the on-site construction drawings; the foundation used for construction is reinforced concrete. To avoid the requirements related to hot work inside the station, prefabrication outside the station is employed. After prefabrication, the components are disassembled and transported to the site where they are installed a second time, thereby avoiding any hot work inside the station. The connection with the existing process pipelines is achieved using flanges. The issue that needs to be addressed now is the positioning of the temporary valve supports fabricated off-site and the fixing of their height; in other words, what methods and materials should be used to construct these supports in such a way that they can be firmly fixed in place, achieving the same proportions and positions as those of the reinforced concrete foundations poured on-site.
For positioning the temporary valve supports that are prefabricated off-site, it is more appropriate to use some structural fixtures, as this is economical and simple. A few experienced installers on site can be brought in; by working together, they can develop this simple mounting device that allows for proportions and positions consistent with those of the foundation on site. Otherwise, the cost of additional measures will be high.