Proposal for Piping Spool Prefab Line(Fixed Type)

8/3/2019 Proposal for Piping Spool Prefab Line(Fixed Type)

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SHANGHAI QIANSHAN PIPING TECHNOLOGY CO., LTD.

Add No.398 ,Jindun Rd , Qixian Industrial Park , Fengxian District , Shanghai City China Tel +86-21-57574707 Fax 021-57574023

Oversea Sales +86-13917320151 After Service:+86-13621986388 E-mail [email protected] Url www.qiansh.com 1

FIXED TYPE PIPING FABRICATIONFACTORY PLANNING & DESIGN

PROPOSAL

The Most Innovative Manufacturer Of

Piping Pre-fabrication EquipmentShanghai Qianshan Piping Technology Co., Ltd

Writing By : Andrew Luo ( ) Tel: +86 13917320151

Date: February 21, 2011

PDF "pdfFactory Pro" www.fineprint.cn
mailto:[email protected]://www.qiansh.com/http://www.fineprint.cn/http://www.fineprint.cn/http://www.fineprint.cn/http://www.fineprint.cn/http://www.fineprint.cn/http://www.qiansh.com/mailto:[email protected]


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CONTENTS

I. Foreword

II. Pipe Prefabrication Overall Program

III. Pipe Prefabrication Process Flow

IV. PDsoft Piping Prefabrication Detail Design Software

System

V. Piping Prefabrication Process Management Software

System

VI. Pipe Beveling Machining SystemVII. Pipe Fittings Beveling & Polishing System

VIII. Pipe Spools Simple Fitting-Up Welding System

IX. Pipe Spools Complex Fitting-Up Welding System

X. NDT (Non Destructive Testing) Piping System

XI. Pipe Conveying System

XII. Piping Prefabrication Production Capacity EstimationXIII. 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 Foreword1. This Planning & Design Program is finally formed based on the successful 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 PrefabricationProduction Line General Layout Plan."

2. As per pipe fabrication production lines, its overall performance will be in the

international & domestic world-class level. 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. 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.

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;

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;

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

fitted-up rapidly; 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 designed for 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



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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)

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

Pipe diameter applicable:DN50-600( 60-610)

Pipe length applicable:0-12M

Pipe weight applicable:0-10 T

Pipe bevel shape: V-,X,U-type, dual-V - Bevel machining speed: 5Min (DN200 SCH40)

Conveying speed :2-20 M / Min

Automatic welding coverage rate: 60% Piping prefabrication ratio:60%-85%

Machining detail design: piping prefabrication detail design software system

Prefabrication process management: piping prefabrication detail design

management software system



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II Piping Prefabrication Overall Program1. Prefabrication Factory Site Component

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

parts: 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.

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. The third part is assorted area, include office, lounge, fittings warehouse,

welding material warehouse, drying room and so on.

The whole prefabrication factory territory constitute a complete piping

prefabrication production system

2. Prefabrication Production Line Setting:

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.

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.

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:

Piping Prefabrication production line is divided into nine areas: piping material stackarea, 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: Piping material stack area is set up with piping material station.



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Pipe beveling polished area is set up with stainless steel, alloy steel, cryogenic steel

pipe fittings and carbon steel pipe fitting polished station.

Pipe cutting area

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

conveying system station.

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.

The other one is for manual plasma and semi-automatic flame cutting &

beveling machining auxiliary station;

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

Simple fitting-up welding area

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 powersource and brand name)

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)

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.

Complex fitting-up welding area

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



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& welding station

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

& welding station

Pipe NDT(non destructive testing) area In the evening, the pipe non-destructive testing is on the fitting-up welding

station or pipe-post treatment on site;

During the day, pipe NDT testing is done inside of piping NDT room or NDT work

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

station.

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

III Piping Prefabrication Process Flow1. Piping prefabrication factory pipe fabricated overall process:

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

fitting-up welding area) pipe complex weld fitting-up welding (complex

fitting-up welding area) welding line NDT-Non-Destructive Test (pipe

nondestructive test area) welding 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: 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) pipe

fabrication heavy rail conveying system 5 or 10-ton overhead crane with a

controller cutting & beveling workstation ( Pipe Conveying System for cut

beveling machine 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 finished products workstation spool piece post treatment station

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

controller finished products workstation finished pipe spools stack station

5-ton L crane with a controller pipe spools loading transported out.3. The carbon steel pipe fabrication production line detail process flow:

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) pipe

spool fabrication heavy rail conveying system 5 or 10-ton overhead crane

with a controller cutting & beveling workstation ( Pipe Conveying System for

bevel cutting machine CNC pipe flame/plasma beveling & cutting machine Pipe Conveying System for bevel cutting machine pipe conveying system

for end beveling machine high speed pipe end beveling machine(compoundbevel station) pipe 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 finished products workstation finished pipe spools stack station

5-ton L crane with a controller pipe spools loading transported out.

IV Piping Detail Design Software System1. 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:

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.

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

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 software-

PD 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 andpiping 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 System1. 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 toeach 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.

Pre-prefabrication: piping information, pipe spools information, welding line

information, material information, etc;

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 pipespools 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,



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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.



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VI Piping Cutting & Beveling Machining System1. 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:

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.

The stainless steel pipe pre-fabrication production line: mainly by roller bench typeCNC 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. 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

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 pipecutting & beveling machine which our company specially makes, uses the pipe

cutting treats and the bevel machining a formation craft. 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. 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:

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. To DN50-600( 60-610mm) 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



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above pipe flame/plasma cutting machine.

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. 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

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 System1. 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 System1. 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,



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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 willbe complete first fitting-up & welding in this area.

5. Pipe spools fitting-up process flow:

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

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:

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:

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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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 gasshield 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 System1. 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:

Carbon steel, stainless steel, alloy steel, cryogenic steel pipe spools: each station ofwork 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:

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.

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 System1. 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 System1. 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: 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. 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:

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.

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

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 470,000inch/year (39,150 inch/month, 1,400 inch/day).

No.Production

LineArea

StationAccount

Welder Account Production Capacity

1Simple fitting-up &

welding area2

Fitting-up machine operator: 2Automatic welding operator: 2

250~350 inch / set / day 2set 27.5 day / month 12month / year =165,000-231,000inch / year

2Complex fitting-up

& welding area1 Electric welder 3

35~45 inch / person / day 2person 27.5 day / month 12month / year =23100-29700inch / year

3

S.S PipeProduction

Line

Pipe posttreatment area 1 Electric welder 1 -

188,100~260,700inch / year

4C.S Pipe

ProductionLine

Simple fitting-up &welding area

2Fitting-up machine operator: 2Automatic welding operator: 2

250~350 inch / set / day 2set 27.5 day / month 12month / year =165,000-231000inch / year

188,100~260,700inch / year

DF "pdfFactory Pro" www.fineprint.cn
http://www.fineprint.cn/http://www.fineprint.cn/http://www.fineprint.cn/


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5Complex fitting-up

& welding area1 Electric welder 3

35~45 inch / person / day 2person 27.5 day / month 12month / year =23100-29700inch / year

6Pipe post

treatment area1 Electric welder 1 -

7 Total 10Fitting-up machine operator: 4Automatic welding operator: 4Electric welder 6

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

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 pass welder

DF "pdfFactory Pro" www.fineprint.cn


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XIII Production Line Equipment Configure List

No.Name of

equipmentItem No application qty unit performance

1. Piping Detail Design And Management Software Piping Detail Design Software SystemAnd Piping Prefabrication Process Management Software System

PDSOFT3DPiping

V1.0 set

1.1Piping Detail

DesignSoftware System

IDFinterfacemodule

V1.0 pcs

Optional

set1.2

Fabrication ProcessManagement

Software System

PDSOFTSPFMS

V1.5 juncti

on

Optional

2 Pipe Cutting And Beveling System(Pipe Cutting & Beveling Machining System And PipeFittings Polishing System)

Production line-1: S.S Automatic Pipe Spool Fabrication Production Line

2.1High Speed Pipe

Cutting & BevelingMachine

FPCBM-12Aa 2 inch-12 inch 1 setPLC Control

Wall thick 18mm

2.2

Pipe ConveyingSystem For

Cutting& BevelingMachine

PLTPS-16C2 2 inch-16 inch 1 set

Feed in and feed

out roller, convey

by electric and PLC

control

2.2

Pipe CrossConveying System

For Cutting &Beveling Machine

PHLTS-16A2 2 inch-16 inch 2 set

Up and down

conveying pipe to

the roller conveyor

to the machine

2.3Pipe Cutting

Length-MeasuringSystem

PCMLS-16A 2 inch-16 inch 1 set

Be equip for cutting &

beveling machine for

length measuring

cutting. PLC control

2.4 Pipe Cutting AndBeveling StationFrame

2 inch-16 inch

Adopt finalized

product directly ,theuser prepare

themselves

2.5Plasma Cutting

Machine2 inch-16 inch 2 set

Adopt finalized

product directly,

the user prepare

themselves



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

2.6

Roller Bench TypeCNC Pipe Flame/

Plasma Beveling &Cutting Machine

BPPBM-24A 4 inch-24 inch 1 set

Flame and Plasma

cutting and CNC

Control For V bevel.

1-18MM (plasma)3-45MM (flame)

2.7

Pipe ConveyingSystem For PlasmaBeveling & Cutting

Machine

PLTPS-24D2 2 inch-24 inch 1 setFeed in and feed out

roller, conveying by

electric

2.8High Speed Pipe

End BevelingMachine

FPEBM-24Aa 4 inch-24 inch 1 setCompound bevel

, , and

dual V, 5-180mm thk

2.9

Pipe Conveying

System For PipeEnd Beveling

Machine

PLTPS-24B2 2 inch-24 inch 1 set

Feed in and out roller,

conveying byelectrical and with

lifting system and turn

around device

2.10Semi Automatic

Flame CuttingMachine

MPFBM-40A 4 inch 2 Setauxiliary cutting

equipment

2.11Pipe Cutting AndBeveling Station

Frame2 inch-24 inch

Adopt finalized

product directly ,the

user prepare

themselves

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

3.1 PPFUM-16A1 3 inch-16 inch 2 set With one fit up head

for SS production line

3.2

Pipe FabricationFast Fitting-Up

Machine PPFUM-24A1 6 inch-24 inch 2 set With one fit up head

for CS production line

3.3 PPFUS-16A 2 inch-16 inch12

pcsFor S.S production

line

3.4

Pipe FabricationAssembled

Carriage PPFUS-24A 6 inch-24 inch12

pcsFor C.S production

line

3.5PPAWM-24Aa(FCAW/GMAW)

2 inch-24 inch 2 set

3.6

Pipe AutomaticWelding Machine PPAWM-24Ab

(SAW)6 inch-24 inch 2 set

With china famousbrand power source

welding process for

root pass, fill in, cap

welding

3.7Manual

Welding/Argon-ArcWelding Machine

3 set Adopt finalized


user prepare



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themselves

3.8STT Semi

Automatic WeldingMachine

Lincoln 3 set

Adopt finalized

product directly, the

user prepare

themselves

3.9Simple Fitting-UpWelding Station

Pipe Racks2 inch-24 inch -

Provide drawing, the

user self-making

3.10Complex Fitting-Up

Welding StationPipe Racks

2 inch-24 inch - Provide drawing, the

user self-making

4 Pipe Or Pipe Spools Conveying System

4.1Pipe Fabrication

Light Rail ConveyingSystem

PPLTS-01T 1T 1 set Optional

4.2Pipe Fabrication

Heavy RailConveying System

PPHTS-10T 10T 2 set Optional

5 ton 1 set

4.3 Overhead Crane10 Ton 1 set

Adopt finalized


user prepare

themselves

4.4 L Crane 5 ton 2 set

Adopt finalized


user prepare

themselves

XIV Institutions & Staffing

1. Piping prefabrication factory institutions

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

Prefabrication factory workshop section setup

According to area to divide and conveying planning in order to

effectively make production organization and management

prefabrication factory setup production workstation as below



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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 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 PeakTime

Basic

Configuration

Remarks

1 Factory DirectorEngineer Or

Technician1 1

2 Production Vice Director Senior Engineer 1 1Worked as a pipingConstruction vice

captain

3 Technical Vice Director Engineer 1 1Worked as a Piping

technician

4 Detail Design EngineerAssistant

Engineer2 2

5Management Software

OperatorSenior High

School1 1

6 Technician Engineer 1 1

7 Quality InspectorEngineer/Senior

Worker2 1

8 Material PlannerEngineer/Assista

nt Engineer2 1



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XV Procedures Programming & Staff Training

1. procedures programming

Before piping prefabrication factory working your should arrange

9 Material KeeperSenior High

School2 1

10 NDT Engineer Engineer 1 1

11Beveling Machine

OperatorJunior High

School1 1 worker

12Plasma Cutting Machine

OperatorSenior High

School1 1 worker

13High Speed Cutting &

Beveling MachineOperator

Junior High

School1 1 worker

14 Cutting Worker

1/3with Some

Experience,

Others Are

Trained Quickly

From Worker

2 1

15Piping Assembled

Worker

1/3with SomeExperience,

Others Are

Trained Quickly

From Worker

6 6

Complex fitting-upwelding segment

with someexperienced workers

16 Argon Root Welder

1/3with Some

Experience

Others Are

Trained Quickly

From Worker

2 2

17 Electrode Welding

ExperiencedAll-Round Welder

Root Pass +

Cap Welding

2 2

18Automatic Welding

OperatorJunior High

School4 4

Trained 2-5 daysmore

19 Crane DriverWith Some

Experience2 1

20 NDT TesterWith Some

Experience3 2

21 Equipment MaintainerWith Some

Experience 2 1One electrician and

one fitterTotal 21 40 33



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specialist to drawing up detail piping prefabrication work procedure

Piping prefabrication work procedure should include piping

prefabrication process main working procedure like

S-00-QSPT-01 factory prefabrication entirely procedure

S-00-QSPT-02 computer data enter procedure

S-00-QSPT-05 second time design procedure

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

S-00-QSPT-11 welding line daily procedure

S-00-QSPT-17 pipe spools marked procedure

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

2. staff training

before piping prefabrication factory work you company should

organize to staff entirely training the content of training main include

piping prefabrication theory training

piping prefabrication procedure training

piping prefabrication skill training

piping prefabrication logos training

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.

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



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prefabrication technology and the piping prefabrication

characteristic comprehensive, thorough and the system

understanding and grasping, can fundamentally overcome softness

management the insufficiency to the piping prefabrication factory

benefit display bottleneck restriction.

Piping factory prefabrication logos include

piping prefabrication factory products is pipe spools

when pipe spools prefabrication does not need to keep the

remainder generally

the piping prefabrication welding line to divide into the simple

welding line and the complex welding line

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



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Piping prefabrication procedure training

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.

Piping prefabrication works procedure to have 22 approximately,

including:

S-00-QSPT-01 factory prefabrication entirely procedure

S-00-QSPT-02 computer data enter procedure

S-00-QSPT-05 second time design procedure

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

S-00-QSPT-11 welding line daily procedure

S-00-QSPT-17 pipe spools marked procedure



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

Piping prefabrication skill training

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.

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.

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



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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.



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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.



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Your firm should (learned operate, guarantee quality as goal) based on

convention training in our company, organizes the specialist to carry on

internal strengthened training (to train speed, to guarantee the quantity

for goal), enhances staff the ability of adaptive. The training courses

will be finalized reasonably according to your practical situation and

enquiries.

Documents

Proposal for Piping Spool Prefab Line(Fixed Type)