Construction plan for insulation of equipment pipelines

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Replacement of insulation covers on all pipes and tanks in the plant area with aluminum plates | Construction plan for projects using stainless steel materials. I. Basis for preparation: 1. “Code for Construction and Acceptance of Insulation Works for Industrial Equipment and Pipes” GBJ126; 2. “Standard for Quality Inspection and Evaluation of Insulation Works for Industrial Equipment and Pipes” GB50185; 3. “General Principles for Insulation Technology of Equipment and Pipes” GB42724; 4. Atlas “Insulation of Pipes and Equipment” 98R419; 5. “Code for Safety in Power Supply at Construction Sites” GB50194. II. Preparation for construction: 1. Technical preparation: Send technical personnel to the site to conduct inspections and understand the design intent. Carry out technical briefings in accordance with the construction plan, relevant codes, and quality evaluation standards. Prepare material plans as well as technical measures for various tasks. It should be equipped with sufficient quantities of various commonly used drugs and medical materials for emergency purposes, as well as skilled workers with years of experience in chemical construction work. At least one supervisor must be present during the construction process, to ensure that the surrounding equipment and the ground are not 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 specifications for chemical engineering construction. He/she should prepare operation guides 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 signs 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 must be returned promptly. The main aspects of preparation for sampling include: 2.1 Whether the type and quantity of insulation materials match those indicated on the label ； 2.2 Has the insulation material been exposed to rainwater, and is there any water accumulation? ； 2.3 Whether the quality parameters of the insulation material, such as its thermal conductivity and bulk density, are up to standard. 3. Labor preparation and personnel mobilization: Given the characteristics of this project, our company will arrange professional construction teams and workgroups with strong technical capabilities and high professional standards to be deployed in a timely manner. Under the unified command of the project management department, these teams will coordinate their efforts to expedite construction progress, improve project quality, and ensure uninterrupted construction operations. Job types 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. Clearly define the special safety measures required for work at heights; where necessary, conduct technical and safety tests, and those who fail these tests shall not be allowed to carry out such 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 specifics of the project, and maintain written records of all this work. 4.3 Prepare the start-up report for this project, obtain the necessary approval for commencement, as well as intermediate inspection reports, construction records, records of concealed works, and quality inspection forms; meanwhile, 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 five key functions: organizing, directing, managing, coordinating, and controlling the construction process. It will also handle coordination among internal and external parties as well as among 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, personnel welfare, and maintaining civilized construction standards. It is fully accountable for the project’s quality, safe and civilized construction practices, schedule adherence, 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 and Equipment Table: Name, Quantity, Arrival Plan, Remarks. Stripping machine: 2; All construction machinery and equipment must arrive at the construction site 3 days before work starts. 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 existing 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 inspection upon completion ； 1.2 For the insulation work of the heat-tracing pipelines, tie them firmly with galvanized iron wire every 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 in horizontal pipelines shall follow the slope of the pipeline. Its longitudinal seam shall be located 15 below the horizontal centerline. ～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 generally form a straight line. 1.4 The circumferential joints of the metal protective layer on pipelines shall be lapped with bulging; the overlap length shall be no less than 50 mm. Apart from the fact that screws should not be used to fix the moisture barrier in longitudinal joints, these joints should be sealed properly and have a neat and aesthetically pleasing appearance. When fixing with screws, the fixing spacing is approximately 200 mm. 1.5 The metal protective coating on the equipment and vertical pipelines shall be fixed in sections to the supports. For the joining of protective layers within the same section, fixed structures and snap-fit structures should be used alternately. 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 panels, 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 must be laid tightly over areas where stiffener plates are present. 2.3 The second layer of insulation material should be offset from the first layer in the same layer, with the layers pressed together; the overlap length should not be less than 50 mm. 3. Installation of the metal outer protective layer 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) Fabrication joint: Make the joint on a manual folding machine (12 mm at the larger end and 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 pipeline’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 pipes, it is 75–100 mm. The circumferential overlap should follow the slope of the pipe, that is, the circumferential joint should face downward. (6) The metal sheath at the insulated end of the straight pipe near the flange should be processed into a sawtooth pattern using diagonal pliers, to protect the insulating material. The outer diameter of the insulation is large, and the spacing between the serrations is also large; conversely, it is smaller. 3.2 Elbow (1) The length of the metal protective layer for the elbow is determined by adding 45 mm for the seam to the outer circumference of the insulation; it must overlap the straight pipe by 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 design 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 methods are the same as those for straight pipes; the metal protective layers of the branch pipes and straight pipes are fixed using pull rivets. 3.4 Precautions for processing and installation (1) Metal protective layers with obvious defects, such as wrinkles, cracks, deep scratches, and corrosion marks, are not allowed to be used. 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 the 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. Upon inspection under 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) Select 5 points evenly from 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 firmly; the supports must not be exposed outside the insulation layer. 5. Check whether the insulation method and the 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, the sampling locations shall be determined as follows: for equipment, three spots shall be randomly inspected per 30 m²; for pipelines, one spot shall be inspected per 20 m. If one of the test points fails, an additional test should be conducted at the nearest location; if still 1/2 of the points fail, that location should be deemed unqualified. 7. The visual inspection of the protective layer shall comply with the following requirements: (1) The circumferential and longitudinal joints of the galvanized iron sheet used for pipe installation shall be perpendicular to each other and form straight lines. (2) The direction of the joints in the galvanized iron sheet used for pipe installation 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 pile items on the installed metal enclosure. Temporary protective measures should be taken for the areas where trampling is inevitable. IV. Technical measures to ensure quality 1. Thoroughly implement and uphold the philosophy of putting quality first. 2. Diligently implement quality standards and technical requirements, ensuring that all construction personnel fulfill their respective duties and responsibilities regarding quality work. 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 sections 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 prepare the necessary construction tools. 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 by being sorted and stacked according to 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 process: assign specific personnel to specific posts, maintain records, and enforce clear 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 attention must also be paid to the overall aesthetic quality of the project. V. Technical measures to ensure safety
1. Implement three-level safety management and establish a safety management system headed 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 abide by the “Safety Technical Regulations for Building Installation Projects” and the “Operational Safety Procedures for Building Installation Projects”. 3.3 The installation and use of temporary electrical circuits and facilities at construction sites must comply with the requirements set forth in the “Safety Technical Code for Temporary Electrical Use in Construction” JGJ46-88 issued by the Ministry of Construction. Electrical circuits must be installed in accordance with the construction plan for temporary power supply; it is strictly prohibited to lay wires or make electrical connections arbitrarily. 3.3.1 The distribution system must be equipped with leakage protectors. It shall comply with the GB6829-86 standard ； 3.3.2 The safety devices of electric machinery and hand-held power 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 \"Standard for Classification of Work at Heights\", a three-level management system is implemented: (1) For heights of 2–5 meters, level 1 management is applied, and it is the responsibility of the professional foreman ； (2) A management level of 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 may be put into use only 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 evaluations shall be conducted monthly, 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 follow the operating procedures and rules and regulations at the construction site; unauthorized commands and illegal operations are prohibited. 3.7 Strictly implement the Fire Protection Regulations of the People’s Republic of China, establish a fire prevention responsibility system and volunteer fire teams, install fire protection facilities that meet regulatory requirements, and ensure they are in good condition and ready for use. 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 each sub-project, thorough safety briefings must be conducted, and regular as well as irregular safety inspections should be carried out at all construction sites to address any issues that arise 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 should be on: 3.11.1 whether safety helmets, safety belts, and safety nets are being used correctly. 3.11.2 Whether safety signs and warning boards are 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 must be in place at its base. 3.11.6 Whether the scaffold is erected in accordance with 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 arrangement 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 setup and testing in order to meet the construction requirements to a high standard. 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 promptly resolve any technical quality issues 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 operations 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 For each section completed during the basic cleaning process, inspections and acceptance checks should be carried out promptly, and a quality report should be issued. Only when the quality inspection is passed can the next construction procedure 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 work is suspended or halted involuntarily, it is necessary to catch up on the project progress in accordance with the construction schedule and flow chart, so that it conforms to the plan. 2.7 The construction worker shall submit a material plan in advance to the material clerk, 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; any problems found should be rectified 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 at the construction site is part of the city’s overall environmental protection efforts, 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 formation. 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 impermeable. 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 \"Noise Limits at Construction Sites\" (GB12523-90). 6. Strengthen the management at the construction site, and in particular prevent phenomena such as intentional knocking, screaming, and rough handling that generate noise, 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