Proposal for Piping Spool Prefab Line(Fixed Type)

SHANGHAI QIANSHAN PIPING TECHNOLOGY CO., LTD.

FIXED FIXE D TYPE PIPING FABRICA ABRICATION TION FACTORY PLANNING & DESIGN PROPOSAL

The Most Innovative Manufacturer Of Piping Pre-fabrication Equipment Shanghai Qianshan Piping Technology Technology Co., Ltd Writing Writing By : Andrew Luo (

) Tel: Tel: +86 13917320151

Date: February 21, 2011 2 011 Add：No.398 ,Jindun Rd , Qixian Qixian Industrial Park , Fengxian Fengxian District , Shanghai City China China Oversea Sales ：+86-13917320151

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CONTENTS I.

Foreword

II.

Pipe Prefabrication Prefabricati on Overall Program

III.

Pipe Prefabrication Prefabricati on Process Flow

IV.

PDsoft Piping Prefabrication Prefabri cation Detail Design Software System

V.

Piping Prefabrication Prefabric ation Process Management Software System

VI.

Pipe Beveling Machining System

VII.

Pipe Fittings Beveling & Polishing System

VIII.

Pipe Spools Spools Simple Fitting-Up Welding System

IX.

Pipe Spools Spools Complex Fitting-Up Welding System

X.

NDT (Non Destructive Destructi ve Testing) Piping System

XI.

Pipe Conveying System

XII.

Piping Prefabrication Prefabric ation Production Capacity Estimation Estimati on

XIII.

Production Line Equipment Configure List

XIV.

Institutions & Staffing

XV.

Procedures Programming & Staff Training Enclosure Enclosure No.1 "Fixed Type Piping Pre-fabrication Factory General Layout Plan"

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I

Foreword

1. This Planning & Design Program is finally formed based on the successful experience experience of our company on the piping prefabrication factory production lines. Pipe production line equipment set-up, please refer to Enclosure No1 "Fixed Type Pipe Prefabrication Production Line General Layout Plan." 2. As per pipe fabrication production production lines, its overall performance will be in the international & domestic world-class level. Ø

Detail design adopts the most advanced "piping prefabrication detail design software system", so that can quickly generate piping line diagram and pipe spools diagram. And by using IDF interface module, design data information of Design Institute can be shared directly, and the seamless docking between design and construction is also achieved.

Ø

Prefabrication management adopts the domestic first-class level software-"piping prefabrication installation management software system", so that we can come out the all-wave informatization management in the whole process of prefabrication.

Ø

Cut & Bevel machining adopts the most advanced domestic the fixed-type NC high speed pipe cutting & beveling machine and the roller-bench type CNC pipe plasma cutting & beveling machine and high speed band saw machine+ End beveling machine , to achieve efficient, NC and length-fixing piping cut & beveling;

Ø

To use of the most advanced NC type piping prefabrication automatic welding machine to achieve high-efficient pipe spools automatic root pass, fill in and cap welding;

Ø

Equipped with piping prefabrication fast fitting-up machine, the pipe spools can be fitted-up rapidly;

Ø

Part of the stations are equipped with digital welding power supply and semi-automatic STT welder, so that it can realize automatic root pass welding and semi-automatic root pass welding.

3. This piping prefabrication production line is is designed for fixed-type. fixed-type. If there are other request, the whole set of piping prefabrication facilities can be designed with certain movable function, so that according to the work array to transfer the whole set piping prefabrication factory to new project site, or transfer core equipments such as high speed pipe cutting & beveling machine, pipe prefabrication plasma beveling & cutting machine, high speed pipe cutting band saw machine, pipe end beveling machine, pipe Add：No.398 ,Jindun Rd , Qixian Qixian Industrial Park , Fengxian Fengxian District , Shanghai City China China Oversea Sales ：+86-13917320151


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fabrication fast fitting-up machine, pipe automatic welding machine and others stuff into containers to do movable work in Pipe Beveling Machining Workstation, Pipe

Fabrication Mechanical Fitting-Up Workstation and Piping Automatic Welding Workstation. 4. According to Piping Prefabrication production line with output of 300,000 O.D-inch diameter / year and 1000 O.D-inch diameter / day(meet your company take process pipe fabrication engineering projects up to 1 Million ton oil refining/year in India)： Ø

Production line annual output: 300,000 O.D –inch/year

Ø

Pipe diameter applicable:DN50-600(φ60-610)

Ø

Pipe length applicable:0-12M

Ø

Pipe weight applicable:0-10 T

Ø

Pipe bevel shape: V-,X,U-type, dual-V -

Ø

Bevel machining speed:≤5Min (DN200 SCH40)

Ø

Conveying speed :2-20 M / Min

Ø

Automatic welding coverage rate: ≥ 60%

Ø

Piping prefabrication ratio:60%-85%

Ø

Machining detail design: piping prefabrication detail design software system

Ø

Prefabrication

process

management:

piping

prefabrication

detail

design

management software system



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II Piping Prefabrication Overall Program 1. Prefabrication Factory Site Component Ø

Prefabrication production line will be locating in India (Asia) and it consists of three parts: ²

The first part is fully closed single production factory, with 80 m length, 26m width and 2080 ㎡. The factory is set up with 1 set of 5-ton overhead crane, and 1 set of 10-ton overhead crane.

²

The second part is the open pipes and finished products stack, on both sides of the stack is set up with one set of 5- ton L crane.

²

The third part is assorted area, include office, lounge, fittings warehouse, welding material warehouse, drying room and so on.

²

The whole prefabrication factory territory constitute a complete piping prefabrication production system

2. Prefabrication Production Line Setting: ²

Setting two piping prefabrication production line inside of the factory, one is the stainless steel production lines, and the other one is carbon steel prefabrication production line. These two production lines share one Light-rail Conveying System to deliver the direct pipe spools from pipe cutting area to Piping simple fitting-up welding area and piping complex fitting-up welding area.

²

Stainless steel prefabrication production line is mainly for stainless steel pipe prefabrication, and it also can be used for carbon steel, cryogenic steel, alloy steel pipes and other pipe spool prefabrication.

²

Carbon steel Prefabrication production line is mainly for carbon steel pipe prefabrication, and it also can be used for stainless steel, cryogenic steel, alloy steel pipes and other pipe spool prefabrication.

3. Production Lines Area Division: Ø

Piping Prefabrication production line is divided into nine areas: piping material stack area, pipe fittings material stack area, piping material cutting area, piping beveling polished area, simple fitting-up & welding area, complex fitting-up & welding area, pipe NDT area, pipe-post treatment area, finished pipe spools area (see Enclosure 1, "Fixed type Piping Prefabrication Production Line General Layout Plan ").

4. Production line station settings: Ø

Piping material stack area is set up with piping material station.


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SHANGHAI QIANSHAN PIPING TECHNOLOGY CO., LTD. Ø

Pipe beveling polished area is set up with stainless steel, alloy steel, cryogenic steel pipe fittings and carbon steel pipe fitting polished station.

Ø

Pipe cutting area ²

The stainless steel pipe fabrication production line: setup 1-cutting & beveling machining station that is for NC high speed pipe cutting & beveling M/C + pipe conveying system station.

²

The carbon steel pipe fabrication production line: setup one CNC pipe flame/plasma beveling & cutting machine+ pipe end beveling machining station, all of machine with conveyor.

²

The other one is for manual plasma and semi-automatic flame cutting & beveling machining auxiliary station;

²

And the capacity of cutting/beveling and conveying will be above O.D 150 /hour, ’’

and total production capacity up to above O.D 1200 /8hours, which will be ”

enough for the requirement of 4 sets of automatic welding station Ø

Simple fitting-up welding area ²

The stainless steel pipe fabrication production line: setup 2 simple fitting-up & welding station, and which 2 stations use to pipe automatic welding machine with China famous brand welding source for FCAW/GMAW/SAW(U.S.A Miller Pipepro450 RFC of RMD-PRO(MIG) ) welding process to do automatic root pass, fill in and cap welding. (welding process as per request to option power source and brand name)

²

The carbon steel pipe fabrication production line: setup 2 simple fitting-up & welding station, and which 2 stations use to pipe automatic welding machine with China famous brand welding source for FCAW/GMAW/SAW(U.S.A Miller Pipepro450 RFC of RMD-PRO(MIG) )welding process to do automatic root pass, fill in and cap welding; (welding process as per request to option power source and brand name)

²

The capacity of fitting-up station and automatic welding station will be above

O.D 135 /hour, and total production capacity up to above O.D 1080 /8hours, if ’’

”

want to improve to capacity can be add to fitting-up and automatic welding station. Ø

Complex fitting-up welding area ²

The stainless steel pipe fabrication production line: set up one complex fitting-up


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& welding station ²

The carbon steel pipe fabrication production line: set up one complex fitting-up & welding station

Ø

Pipe NDT(non destructive testing) area ²

In the evening, the pipe non-destructive testing is on the fitting-up welding station or pipe-post treatment on site;

²

During the day, pipe NDT testing is done inside o f piping NDT room or NDT work station

Ø

The pipe-post treatment area is set up with a heat treatment station and a rework station.

Ø

Placing of finished pipes is set up with the finished products stack station.

III Piping Prefabrication Process Flow 1. Piping prefabrication factory pipe fabricated overall process: Ø

Placing of raw materials (pipes stack, pipe fittings stack)

→pipe

beveling

machining / pipe fittings beveling polishing (pipe cutting area / pipe fittings beveling polished area)

→pipe

simple welding line fitting-up welding (simple

→pipe

fitting-up welding area)

complex weld fitting-up welding (complex

area)

→welding

nondestructive test area)

→welding

fitting-up

welding

line

NDT-Non-Destructive

Test (pipe

line rework / heat treatment (pipe-post

treatment) →placing of finished products (finished products stack area)

2. The stainless steel pipe fabrication production line detail process flow: Ø

Stock material from supplier→5-ton L crane with a controller →material workshop section (pipe material stack station)

→(5-ton

fabrication heavy rail conveying system controller

→5

→pipe

or 10-ton overhead crane with a

& beveling workstation (Pipe Conveying System for cut

→cutting

beveling machine

L crane with a controller)

→CNC

high speed pipe cutting & beveling machine

→Pipe

conveying system for cut beveling machine→ cutting & beveling workstation (polishing station)→pipe fabrication light rail conveying system

→simple

fitting-up & welding workstation (simple pipe spools fitting-up and tack welding →root

pass welding

→

cap welding)→5 or 10-ton single beam and remote

controlled overhead crane

→complex

fitting-up & welding workstation(complex

pipe spools fitting-up welding station)→5 or 10-ton crane with a controller →testing

workstation（nondestructive testing station）→5 or 10-ton crane with a


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controller →pipe

products workstation（spool piece post treatment station）

→finished

fabrication heavy rail conveying system→5-ton L crane with a

controller →5-ton

products workstation（finished pipe spools stack station）

→finished

L crane with a controller →pipe spools loading transported out.

3. The carbon steel pipe fabrication production line detail process flow: Ø

Stock material from supplier→5-ton L crane with a controller →material workshop section (pipe material stack station)

→(5-ton

L crane with a controller)

spool fabrication heavy rail conveying system with a controller

→cutting

bevel cutting machine →Pipe

→5

→pipe

or 10-ton overhead crane

& beveling workstation (Pipe Conveying System for

→CNC

pipe flame/plasma beveling & cutting machine

Conveying System for bevel cutting machine →pipe conveying system

for end beveling machine bevel station)

→pipe

→high

speed pipe end beveling machine(compound

conveying system for end beveling machine

→cutting

&

beveling workstation (polishing station)→pipe spool fabrication light rail

conveying system

→simple

fitting-up & welding workstation (simple pipe spools

fitting-up and tack welding →root pass welding → cap welding)→5 or 10-ton single

beam and remote controlled overhead crane

→complex

fitting-up & welding

workstation(complex pipe spools fitting-up welding station)→5 or 10-ton crane with

a controller

→testing

workstation（nondestructive testing station）→5 or 10-ton

crane with a controller →finished products workstation（spool piece post treatment station）→pipe fabrication heavy rail conveying system→5-ton L crane with a

controller →5-ton

→finished

products workstation（finished pipe spools stack station）

L crane with a controller →pipe spools loading transported out.

IV Piping Detail Design Software System 1. Piping detail design system：before starting or in process of the construction object， according the flat and elevation working plan (or original line diagram) or intermediate file provided by main contractor, redrawing(or re-machining) or generate piping drawing, which meet the Piping factory prefabrication request, and also the line diagram for pipe field installation and management. 2. Only handle the original line diagram provided by designing institute is not enough, the detail design is needed also, there are several reasons: Ø

Original line diagram can not meet the requirements of pipe prefabrication


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installation: it has disadvantage of illogical subsection and lacking of relevant identifier, etc. For example, original line diagram lack the identifier of welding joint No., piping No., straight tube baiting size and onsite welded junction, etc. Ø

Can not provide piping drawing but only original line diagram, this can not meet the requirements of modern piping prefabrication

Ø

.

Detail design can reduce duplication of labor, improve work efficiency, to ensure the work consistency and synchronicity.

3. It is one of the most important index to measure the advanced degree of Piping prefabrication factory. This piping detail design are via Plant design system softwarePD Soft 3D Piping “Piping prefabrication design system” of Beijing Zhongke Fulong Computer Technology Co., LTD, so it is suit for different generated mode and level. 4. By using PD soft 3D Piping, on the basis of establishment of pipe grade database and piping database, we can build pipe model block-by-block, automatic generate the line diagrams (for onsite installation) and pipe design(for prefabrication factory ). Identification automatically generated are: welding joint No., piping No., straight tube baiting size and bill of materials, etc. 5. There are five steps when using PD soft 3D Piping to do the pipe detail design： establish the pipe grade database, establish the piping database, draw the piping three-dimensional model, automatic generate the line diagrams, automatic generate pipe spools diagrams.


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6. We use IDF interface module to share design information module. The function of IDF interface module is to convert the IDF document generated by ISOGEN of imported PDS or PDMS into PDSOFT 3DPiping model and the corresponding database. On the basis of this, the line diagrams and piping diagrams will be generated automatic so that we don’t need to spend a lot of energy and financial resources to re-establish the model.


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V Prefabrication Process Management System 1.

By using “PDSOFT Piping Prefabrication & Installation Management Software” joint developed by Beijing Zhongke Fulong Computer Technology Co., LTD. and our company (Shanghai Qianshan Piping Technology Co., Ltd), we can realize the


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effective management of huge number of pipe fittings, welding lines and pipe spools in the prefabrication process, and make the informatization of technical management, quality control, materials management, testing（NDT） management, progress control, etc possible in the piping prefabrication process, also make the management depth to each piping, each pipe phrase, each welding line and each welder, etc.

2. The software is developed by strong joint, so it is powerful and practical. Its outstanding function is Piping Prefabrication Management, NDT Management, Material and Mixture Management, materials traceability management. 3. The software can facilitate the entry of various piping prefabrication information. If the detail design is generated by PDSOFT 3DPiping, we can lead-in the information of pipe lines, pipe spools, welding lines and materials by using the leading-in function of the software. Ø

Pre-prefabrication: piping information, pipe spools information, welding line information, material information, etc;

Ø

Process of prefabrication: welding line fitting-up welding information, pipe spools fitting-up welding information, pipe spools inspection information, pipe spools ex-works information, NDT information, material received information, material delivered information, test day commission information, etc.


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4. The software can automatic mix the material according to the line diagrams and pipe spools diagrams: mark with the special identifications for the line diagrams and pipe spools diagrams whose materials are in position and ready to prefabricate, and automatically print out materials receipt when it is needed for arranging the production.


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5. The software can enquire crossly all kinds of information.

6. The software can easily output and print various statements: material shortage bill, Add：No.398 ,Jindun Rd , Qixian Industrial Park , Fengxian District , Shanghai City China Oversea Sales ：+86-13917320151

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finished work list, un-inspected pipe spools bill, unfinished pipe spools bill, ex-worked pipe spools bill, welders’ once welding pass rate, etc.

7. The software can automatically generate and print the technical data which should be handed in keeping with the relevant specifications. Add：No.398 ,Jindun Rd , Qixian Industrial Park , Fengxian District , Shanghai City China Oversea Sales ：+86-13917320151

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VI Piping Cutting & Beveling Machining System 1. The whole of piping cutting & beveling machining system is composed of steel station structure, beveling machining equipments and beveling machining conveying system. 2. The whole of pipe cutting area is set up with one 800MM height steel station structure, so that it is easy for placing, rolling over and beveling the pipes and to realize the ordered pair between beveling machining and conveying system. 3. According to the pipe material, wall thickness, the machining size, efficiency and costs of machining requirements, to option the reasonable bevel machining methods below: Ø

The stainless steel pipe pre-fabrication production line: machining mainly by fixed type NC high speed pipe cutting & beveling machine for beveling of standard wall thickness stainless steel, carbon steel, cryogenic steel, alloy steel etc.

Ø

The stainless steel pipe pre-fabrication production line: mainly by roller bench type CNC high speed pipe flame/plasma beveling & cutting machine for beveling of standard wall thickness carbon steel, stainless steel, cryogenic steel, alloy steel, and high speed pipe end beveling machine for thick-wall thickness & compound bevel shape.

Ø

When carbon steel and stainless steel or others workload is imbalanced, the stainless steel production line and carbon steel production line can be exchange


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using.(suit for diameter ≤ DN300mm) 4. NC High speed pipe cutting & beveling machine bevel machining technology Ø

DN≤300 the carbon steel, alloy steel, cryogenic steel and the stainless steel pipe (estimated total work load is above 95%), uses vacancy-type NC high speed pipe cutting & beveling machine which our company specially makes, uses the pipe cutting treats and the bevel machining a formation craft.

Ø

High speed pipe cutting & beveling machine vacancy (hollow) of inside, pipe goes into machine directly, With the triangle V tool bit vertical pipe machining, completes the pipe cut-off and two bevel process simultaneously; the cutting remainder unnecessary so the raw material can be saved, cutter rest high speed rotate, generally completes the work in 5 minutes, realizes the bevel highly effective machining truly.

Ø

As well as be equipped for pipe cross （lateral）conveying system for pipe up and down from the pipe roller conveying system of cutting and beveling machine to improve automation level.


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5. Roller-bench type CNC pipe flame/plasma beveling & cutting machine bevel machining technology: Ø

Roller-bench type CNC pipe flame/plasma beveling & cutting machine is generally multiple-axis consistent with a simplified version of Cutting Machine, has


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custom-made special for pipe fabrication factory pipe bevel fast cutting & beveling. Needed to cut the pipes when the pipes transport into the roller conveyor bench, adopt roller-bench driven the pipe rotation, cutting carriage along the track for cut the pipes of subsection length-measuring cutting. Ø

To DN50-600(φ60-610mm) of the stainless steel and wall thickness not too thick carbon steel，carbon steel, alloy steel, cryogenic steel pipe （plasma cutting ≤ 18mm;flame cutting ≤45mm）, use this machine, with its support of a plasma cutting torch, or one flame cutting torches, complete to pipe cutting materials and one bevel machining simultaneously.


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6. High speed pipe end beveling machine bevel machining technology connecting with Add：No.398 ,Jindun Rd , Qixian Industrial Park , Fengxian District , Shanghai City China Oversea Sales ：+86-13917320151

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above pipe flame/plasma cutting machine. Ø

Use to high speed pipe end beveling machine to machining thick-wall thickness (up to 180mm) of stainless steel, carbon steel, alloy steel, cryogenic steel pipes and compound bevel shape machining.

Ø

The pipe conveying system for pipe end beveling machine with turn around device, in order to both end of pipe bevel machining if need compound bevel shape’s pipes.


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7. Semi-automatic flame cutting machine bevel machining technology Ø

Adopt semi-automatic flame cutting machine bevel machining is a practical and reliable way, and regardless of the pipe size diameter, is one kind very good supplemented of the piping highly effective bevel machining method .

VII Pipe Fittings Beveling and Polishing System 1. The whole Pipe Fittings beveling and polishing system is composed of steel station structure, disk sander and pipe fittings traveling bogie. 2. The whole pipe fittings beveling area is set up with one 1000MM height steel station structure, so that it is easy for placing and polishing the pipe fittings. 3. Pipe fittings beveling area is divided into two carbon steel, alloy steel, cryogenic steel polishing station and two stainless steel polishing station. Pipe fittings are polished by the disk sander by manually. 4. A set of polished pipe fittings will be transported to pipe simple fitting-up welding station in the traveling bogie by crane.

VIII

Pipe Spools Simple Fitting-Up Welding System

1. Pipe spools Simple Fitting-up & welding System is composed of five parts, they are: steel station structure, assembled carriage, pipe fabrication fast fitting-up machine, Add：No.398 ,Jindun Rd , Qixian Industrial Park , Fengxian District , Shanghai City China Oversea Sales ：+86-13917320151

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root pass welding equipments (argon arc welder and STT semi-automatic arc welder) and automatic welding machine(include automatic root pass weld). 2. The whole simple fitting-up welding area is set up with one 1000MM steel station structure, so that it is easy for placing straight pipe spools, welding line assembly, welding line rendering, pipe spools rolling and realize the ordered joint between piping prefabrication automatic welding machine. 3. For the space between the channel steel of the steel station structure is too big, so the assembled carriage is set up to support and adjust the height when fit-up the shorter pipes and pipe fittings. 4. The both of stainless steel pipe fabrication production line and carbon steel pipe fabrication production line are set up two simple fitting-up & welding stations. That all the welding lines in the pipe spools can be finished by automatic welding machine will be complete first fitting-up & welding in this area. 5. Pipe spools fitting-up process flow: Ø

To fitting-up the welded junction mainly by mechanically and assisted by manually;

Ø

Each station is set up with one set of pipe prefabrication fast fitting-up machine to fast fit-up the pipe and fittings with below DN600(C.S production line) and DN 400(S.S production line)


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6. Root Pass Welding Process Flow: Ø

Both of the stainless steel pipe fabrication production line and carbon steel pipe


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fabrication production line: each station is set up with four argon-arc welding machine for root pass welding. Or with pipe automatic welding for root pass, fill in pass & cap welding(proposed); Or pipe automatic root pass welding machine for pipe automatic root pass welding.


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7. Fill In And Cap Welding Process Flow: Ø

Both of the S.S and C.S pipe fabrication production line: setup two automatic pipe welding stations for each production line, and which all of stations are using to pipe automatic welding machine (MIG/FCAW) to do high efficient root pass, fill in pass and cap welding; As well as can be using to submerged arc welding (SAW) to do fill in pass and cap welding with best efficiency if necessary.


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SHANGHAI QIANSHAN PIPING TECHNOLOGY CO., LTD. Ø

Pipe fabrication Automatic Welding Machine：its application is broadly (half-finished pipe spools of various DN and structures), welding efficiency is excellent (welding pipe spools assembly fast, To use double and thin welding wire for submerged arc welding, and single and thick welding wire for submerged arc welding; or CO2 gas shield welding to realize continuous welding), Operability is very good(applicable and easy to operate even if you are a new user within a short period of time), surface finishing is good (the welding gun will always be positioned in the optimum position),Testing rate is high.

IX Pipe Spool Complex Fitting-Up Welding System 1. Pipe spools complicated combination welding system by steel structure work frame、 the group of supporting frame, the manual welding /argon arc welding machine three parts are composed 2. The entire complex group butt weld area set up a steel structure work frame, it is height 800mm, to facilitate the piling up of semi-finished products, complex Welding line butt joint, complex welding line root pass welding. 3. Spacing between the steel structure location channel steel is large, for is advantageous for the short pipe, the pipe fittings fit-up to the time support and height adjust, has set up movable butt joint supporting frame 4. Both of S.S and C.S pipe fabrication production line all set up one complex fitting-up welding stations ,for it is unable weld of welding line by automatic welding machine on the pipe spools welding ,all of these welding lines are putting this area to process complex fitting-up & butt welding completely. 5. Pipe spools fitting up and butt joint welding technology: directly with manual or draws support from 5 tons hoisting with overhead process butt joint on the assembly place to be right. 6. Pipe Spools Root Pass Welding Technology: Ø

Carbon steel, stainless steel, alloy steel, cryogenic steel pipe spools: each station of work set up 1 sets manual welding machine/argon arc welding machine and 1 set STT semi-automatic welding machine, for DN≤250 with manual argon arc welding machine for root pass welding, for DN≥300 with STT semi-automatic root pass welding .

7. Pipe spools cap welding technology: Ø

Carbon steel, alloy steel, cryogenic steel piping: using has been set up 2 sets of


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manual welding and argon arc welding machine, with manual cap welding. Ø

Stainless steel piping: using has been set up 2 sets of manual welding and argon arc welding machine, with manual cap welding.

X NDT(non destructive testing) Piping System 1. In the evening, the pipe spools non-destructive testing on the fitting-up welding station of work in place or pipe of the welder after-treatment on the spot; During the day, pipe NDT process inside of the piping NDT room or NDT work station 2. Piping NDT room or NDT workstations set up at the end of workshop. With operating room with five tons of traveling crane will be put pipe suspended to the track of small cars, then use artificial will put the car into the NDT room, or NDT workstations process the NDT. This part of the work by the user responsible for themselves. 3. Need amend of return treatment welding line is repairing of the post-machining areas, then NDT again.

XI Piping Conveying System 1. To set up the logical piping conveying system to ensure the transportation in, between stations and between workstations fluent, high-efficiency and safe. 2. Piping Spaces Conveying System: Ø

Inside of workshop conveying system: be set up with 1 set of 5-ton, 1 set of 10-ton overhead crane mainly to transport the pipe spools along with and upright of the production line.

Ø

Outside of workshop conveying system: both pipe materials stack and finished pipe spools stack area are set up with 1 sets of 5-ton L crane, one is mainly used for pipes transferring and pipe spools transferring in and out of stacks if necessary.

3. Piping ground conveying system: Ø

In order to transfer quickly the pipes from out-of-door pipes stack area into in-door pipe cutting area and transfer quickly from complex fitting-up welding area out to pipe spools finished stack area, there are 2 heavy rail conveying systems installed if necessary.

Ø

In order to reduce the distance of transportation by using crane along with the production line and avoid the collision between the cranes, in order to improve the pipe spools long-distance transportation along with the production line after cutting, improve the work efficiency and reduce operating risk, one light rail conveying system is set up between pipe cutting area and pipe spools fitting-up welding area.


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After Service:+86-13621986388 41

Tel：+86-21-57574707






After Service:+86-13621986388 42

Tel：+86-21-57574707






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Tel：+86-21-57574707





XII Production Line Production Capacity Estimation Production capacity estimation as show in the below form ，design production capacity of the whole prefabrication factory is

Ø

above 350,000~520,000 O.D inch/year. If consider the load as 90%, the average production capacity of the whole prefabrication factory can reach 470,000

Ø

inch/year (39,150 inch/month, 1,400 inch/day). No.

Production Line

Area

Station Account

Welder Account

Production Capacity （250~350）inch / set / day×（2

Simple fitting-up &

1

welding area

2

Fitting-up machine operator: 2

set ） × （ 27.5 day / month ×12

Automatic welding operator: 2

month / year）=165,000-231,000 inch / year

S.S Pipe Production 2

Line

Complex fitting-up & welding area

1

Electric welder ：3

（35~45）inch / person / day ×2

188,100~260,700

person×（27.5 day / month×12

inch / year

month / year ） =23100-29700 inch / year

Pipe－post

3

treatment area C.S Pipe

4

Production Line

1


（250~350）inch / set / day×（2

Simple fitting-up & welding area

2

Fitting-up machine operator: 2

set ） × （ 27.5 day / month ×12

188,100~260,700


month / year ）=165,000-231000

inch / year

inch / year

44



（35~45）inch / person / day×2

5

Complex fitting-up & welding area

1


person×（27.5 day / month×12 month / year ） =23100-29700 inch / year

6

Pipe－post treatment area

1


-

Fitting-up machine operator: 4 7

Total

10


376,200~521,400 O.D inch/year

Electric welder ：6 This capacity is estimating as per normal production, more higher capacity as per testing; if with root pass weld by automatic welding, no need argon root p ass welder

45



XIII No.

Production Line Equipment Configure List Name of equipment

Item No

application

qty

unit

performance

1. Piping Detail Design And Management Software（Piping Detail Design Software System And Piping Prefabrication Process Management Software System） PDSOFT 1.1

Piping Detail

3DPiping

Design

IDF

Software System

interface

V1.0

set Optional

V1.0

pcs

module Fabrication Process 1.2

Management Software System

PDSOFT SPFMS

set V1.5

Optional

juncti on

2 Pipe Cutting And Beveling System(Pipe Cutting & Beveling Machining System And Pipe Fittings Polishing System) Production line-1: S.S Automatic Pipe Spool F abrication Production Line High Speed Pipe 2.1

Cutting & Beveling

FPCBM-12Aa

2 inch-12 inch

1

set

Machine

2.2

System For Cutting& Beveling

PLTPS-16C2

2 inch-16 inch

1

set

by electric and PLC control

Pipe Cross

Up and down

Conveying System For Cutting &

PHLTS-16A2

2 inch-16 inch

2

set

Length-Measuring

the roller conveyor Be equip for cutting &

PCMLS-16A

2 inch-16 inch

1

set

System

beveling machine for length measuring cutting. PLC control Adopt finalized

Pipe Cutting And Beveling Station

conveying pipe to to the machine

Pipe Cutting

2.4

out roller, convey

Machine

Beveling Machine

2.3

Wall thick≤18mm Feed in and feed

Pipe Conveying 2.2

PLC Control

product directly ,the

2 inch-16 inch

user prepare

Frame

themselves Adopt finalized

2.5

Plasma Cutting Machine

2 inch-16 inch

2

set

product directly, the user prepare themselves

46



Production line-2: C.S Automatic Pipe Spool Fabrication Production Line Flame and Plasma

Roller Bench Type 2.6

CNC Pipe Flame/ Plasma Beveling &

cutting and CNC

BPPBM-24A

4 inch-24 inch

1

set

1-18MM (plasma)

Cutting Machine

3-45MM (flame)

Pipe Conveying 2.7

System For Plasma Beveling & Cutting

Control For V bevel.

Feed in and feed out

PLTPS-24D2

2 inch-24 inch

1

set

roller, conveying by electric

Machine High Speed Pipe 2.8

End Beveling

Compound bevel

FPEBM-24Aa

4 inch-24 inch

1

set

Machine

dual V, 5-180mm thk Feed in and out roller,

Pipe Conveying 2.9

System For Pipe End Beveling

conveying by

PLTPS-24B2

2 inch-24 inch

1

set

around device

Semi－Automatic Flame Cutting

electrical and with lifting system and turn

Machine

2.10

Ｕ , Ｘ , Ｖ and

MPFBM-40A

≥4 inch

2

Set

auxiliary cutting equipment

Machine

Adopt finalized

Pipe Cutting And 2.11

Beveling Station


2 inch-24 inch

user prepare

Frame

themselves

3 Pipe Fitting-Up And Welding System Pipe Simple Fitting-Up Welding System And Pipe Complex Fitting-Up Welding System For Both Of S.S And C.S Production Line 3.1

Pipe Fabrication

PPFUM-16A1

3 inch-16 inch

2

set

2

set

Fast Fitting-Up 3.2

Machine

PPFUM-24A1

6 inch-24 inch

3.3

Pipe Fabrication

PPFUS-16A

2 inch-16 inch

PPFUS-24A

6 inch-24 inch

Assembled 3.4

Carriage

PPAWM-24Aa

3.5 Pipe Automatic 3.6

Welding Machine

(FCAW/GMAW)

PPAWM-24Ab (SAW)

2 inch-24 inch

1 2 1 2 2

pcs pcs set

for SS production line With one fit up head for CS production line For S.S production line For C.S production line With china famous brand power source welding process for

6 inch-24 inch

2

set

Welding/Argon-Arc Welding Machine

root pass, fill in, cap welding

Manual 3.7

With one fit up head

Adopt finalized

3

set

product directly ,the user prepare 47


SHANGHAI QIANSHAN PIPING TECHNOLOGY CO., LTD. themselves Adopt finalized

STT Semi－ 3.8

Automatic Welding

Lincoln

3

set

product directly, the user prepare

Machine

themselves

Simple Fitting-Up 3.9

Welding Station

2 inch-24 inch

-

㎡

2 inch-24 inch

-

㎡

Provide drawing, the user self-making

Pipe Racks Complex Fitting-Up 3.10

Welding Station Pipe Racks

4

Provide drawing, the user self-making

Pipe Or Pipe Spools Conveying System Pipe Fabrication 4.1

Light Rail Conveying

PPLTS-01T

1T

1

set

Optional

10T

2

set

Optional

5 ton

1

set

Adopt finalized

System Pipe Fabrication 4.2

Heavy Rail

PPHTS-10T

Conveying System

4.3


Overhead Crane 10 Ton

1

user prepare

set

themselves Adopt finalized

4.4

L Crane

5 ton

2

set

product directly ,the user prepare themselves

XIV

Institutions & Staffing

1. Piping prefabrication factory institutions Ø

Setup

always

belong

to

Project

Department

leader’s

piping

prefabrication factory ， according to your feature set up several workgroup and several production workshop section under the piping prefabrication factory Ø

Prefabrication factory workshop section setup ²

According to area to divide and conveying planning，in order to effectively make production organization and management ， prefabrication factory setup production workstation as below ： 48



material stack workstation 、 application workstation 、 cutting & beveling workstation 、 simple fitting-up & welding workstation 、 complex fitting-up & welding station、testing workstation、finished products workstation、hoisting with crane workstation ²

Material workstation take charge of pipe material stacking area、pipe fittings material stacking area task ， application workstation take charge of pipe painting area task，cutting workstation take charge of pipe fittings welding polishing area and pipe cutting area task，simple fitting-up & welding workstation take charge of simple fitting-up welding area task，complex workstation take charge of complex fitting-up welding area task，finished product workstation take charge of pipe － post treatment area and pipe spools finished product stacking area task，hoisting with crane workstation take charge of whole conveying system。

2. Piping Prefabrication Factory Staffing Account No.

Proposed Posts

Requirements

Peak Time

1

Factory Director

Engineer Or Technician

1

Basic Configurat

Remarks

ion 1 Worked as a piping

2

3 4

Production Vice Director Senior Engineer

Technical Vice Director Detail Design Engineer

Engineer Assistant Engineer

Management Software

Senior High

Operator

School

6

Technician

Engineer

7

Quality Inspector

8

Material Planner

5

Engineer/Senior Worker Engineer/Assista nt Engineer

1

1

Construction vice

1

1

captain Worked as a Piping technician

2

2

1

1

1

1

2

1

2

1

49


SHANGHAI QIANSHAN PIPING TECHNOLOGY CO., LTD. Senior High

9

Material Keeper

10

NDT Engineer

Engineer

Beveling Machine

Junior High

Operator

School

Plasma Cutting Machine

Senior High

Operator

School

11 12

School

High Speed Cutting & 13

Junior High

Beveling Machine

School

Operator

2

1

1

1

1

1

worker

1

1

worker

1

1

worker

2

1

1/3with Some Experience,

14

Cutting Worker

Others Are Trained Quickly From Worker 1/3with Some

15

Complex fitting-up

Experience,

Piping Assembled

Others Are

Worker

6

6

Trained Quickly

welding segment with some experienced workers

From Worker 1/3with Some Experience，

16

Argon Root Welder

Others Are

2

2

2

2

4

4

2

1

3

2

2

1

40

33

Trained Quickly From Worker Experienced

17

Electrode Welding

All-Round Welder （Root Pass +

Cap Welding

18

Automatic Welding

Junior High

Operator

School

19

Crane Driver

20

NDT Tester

21

Equipment Maintainer Total

XV

With Some Experience With Some Experience With Some Experience

21

Trained 2-5 days more

One electrician and one fitter

Procedures Programming & Staff Training

1. procedures programming Ø

Before piping prefabrication factory working ， your should arrange 50



specialist to drawing up detail piping prefabrication work procedure。 Piping

prefabrication

work

procedure

should

include

piping

prefabrication process main working procedure，like ： ²

S-00-QSPT-01 ”factory prefabrication entirely procedure”

²

S-00-QSPT-02 ”computer data enter procedure”

²

S-00-QSPT-05 “second time design procedure”

²

S-00-QSPT-09 “material label of color controlling procedure”

²

S-00-QSPT-11 “welding line daily procedure”

²

S-00-QSPT-17 “pipe spools marked procedure”

²

S-00-QSPT-19 “pipe spools check and accept procedure”

2. staff training Ø

before piping prefabrication factory work ， you company should organize to staff entirely training，the content of training main include：

Ø

²

piping prefabrication theory training

²

piping prefabrication procedure training

²

piping prefabrication skill training

piping prefabrication logos training ： ²

if leaders step logos is not in advance impossible at the right moment to purchase piping the prefabrication monomer equipment, provides piping the prefabrication workstation or constructs the piping prefabrication factory; administer step and operation step logos if cannot follow, even if purchased the piping prefabrication monomer equipment, has provided the piping prefabrication workstation or has constructed the piping prefabrication factory, also was impossible the function and the efficiency which displayed well its should have.

²

Should to leaders step, administer step and operation step carries on the brainwashing -like piping prefabrication logos training service.Only

then

has

achieved

from

logos

to

the

piping 51



prefabrication

technology

and

characteristic

comprehensive,

the thorough

piping and

prefabrication the

system

understanding and grasping, can fundamentally overcome softness management the insufficiency to the piping prefabrication factory benefit display bottleneck restriction. Ø

Piping factory prefabrication logos include： ²

“piping

prefabrication factory products is pipe spools”

²

“when

pipe spools prefabrication does not need to keep the

remainder generally” ²

“the

piping prefabrication welding line to divide into the simple

welding line and the complex welding line ²

“piping

material divides into prefabrication material and scene

material, prefabrication material (for example pipe, pipe fittings) does not carry on the scene, scene material (for example valve, bolt, filling piece)does not carry on fabrication

52



Ø

Piping prefabrication procedure training ： ²

Piping prefabrication work procedure uses to ensure each working procedure strictly and requests according to the stipulation method to carry on the work, had such set to work procedure to be possible to reduce greatly to human's dependence, special under personnel fluidity big environment background.

Ø

Piping prefabrication works procedure to have 22 approximately, including: ²

S-00-QSPT-01 ”factory prefabrication entirely procedure”

²

S-00-QSPT-02 “computer data enter procedure”

²

S-00-QSPT-05 “second time design procedure”

²

S-00-QSPT-09 “material label of color controlling procedure”

²

S-00-QSPT-11 “welding line daily procedure”

²

S-00-QSPT-17 “pipe spools marked procedure” 53


SHANGHAI QIANSHAN PIPING TECHNOLOGY CO., LTD. ²

Ø

S-00-QSPT-19 “pipe spools check and accept procedure”

Piping prefabrication skill training： ²

After piping carries on factory prefabrication, will carry on the one line production according to the working procedure. The single channel

working

procedure

technology

simple

nature,

the

engineering project seasonal characteristic and the resilience uncertainty, after causes to employ the non-skilled worker to carry on the short time to strengthen training to become on the mount guard work is possible and is essential. ²

Piping factorization prefabrication or factory prefabricate employ the non-skilled worker massively, can reduce the manpower cost greatly. If arranges to have the traditional piping prefabrication

work

experience technical worker to participate in piping factory prefabrication, also needs to have the adaptation process. ²

In view of the above situation, your firm should develop to has 54



traditional piping prefabrication work experience technical worker's compatible training and does not have piping prefabrication work experience technical worker's skillful training. Skillful training involved the main kind of work in a factory to include: the pipe cutting labor, automatic welding operator, the labor with assembly pipe, the backing welder with argon arc welding, the backing welder with STT gas welding.

55



篇

三、

Ø

Modernized

piping

prefabrication

factory

request

carries

on

prefabrication according to pipe the segments drawing (not single line drawing), need carry on pipe detail design (second time design), needs training and provides Engineer for detail design. 56


Proposal for Piping Spool Prefab Line(Fixed Type)

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