Proposal For Piping Spool Prefab Line Fixed Type PDF

SHANGHAI QIANSHAN PIPING TECHNOLOGY CO., LTD.
FIXED TYPE PIPING FABRICATION

FACTORY PLANNING & DESIGN
PROPOSAL
The Most Innovative Manufacturer Of

Piping Pre-fabrication Equipment
Shanghai Qianshan Piping Technology Co., Ltd
Writing By : Andrew Luo () Tel: +86 13917320151
Date: February 21, 2011
AddNo.398 ,Jindun Rd , Qixian Industrial Park , Fengxian District , Shanghai City China
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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 System
VII.
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 Estimation
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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Foreword
1. 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 Prefabrication
Production 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 Program

1. 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 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:
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 & beveling
machining 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 power
source 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 Flow

1. 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 supplier5-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 workstationnondestructive testing station5 or 10-ton crane with a
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controller finished products workstationspool piece post treatment station

pipe fabrication heavy rail conveying system5-ton L crane with a
controller finished products workstationfinished 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 supplier5-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(compound
bevel 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 workstationnondestructive testing station5 or 10-ton
crane with a controller finished products workstationspool piece post treatment
stationpipe fabrication heavy rail conveying system5-ton L crane with a
controller finished products workstationfinished pipe spools stack station
5-ton L crane with a controller pipe spools loading transported out.
IV Piping Detail Design Software System

1. Piping detail design systembefore 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 the
requirements 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 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 dont 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, testingNDT 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.
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 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,
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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 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:
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 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.
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
DN300 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.
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 crosslateralconveying 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 steelcarbon steel, alloy steel, cryogenic steel pipeplasma 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 shapes 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 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,
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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:
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 Machineits 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:
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 DN250 with manual argon arc welding
machine for root pass welding, for DN300 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 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:
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.
Tel+86-21-57574707
40
Fax021-57574023
Urlwww.qiansh.com

41
Tel+86-21-57574707
Fax021-57574023
Urlwww.qiansh.com

42
Tel+86-21-57574707
Fax021-57574023
Urlwww.qiansh.com

43
Tel+86-21-57574707
Fax021-57574023
Urlwww.qiansh.com

XII Production Line Production Capacity Estimation

Production capacity estimation as show in the below formdesign 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 470,000
inch/year (39,150 inch/month, 1,400 inch/day).
No.
Production
Line
Simple fitting-up &

welding area
S.S Pipe
Production
Line
Complex fitting-up
& welding area
Pipepost
Area
treatment area
C.S Pipe
Production
Line
Simple fitting-up &

welding area
Station
Account
Welder Account
Production Capacity
Fitting-up machine operator: 2

Automatic welding operator: 2
250~350inch / set / day2

set27.5 day / month12
month / year=165,000-231,000
inch / year
Electric welder3
35~45inch / person / day 2

person27.5 day / month12
month / year =23100-29700
inch / year
Electric welder1

250~350inch / set / day2

set27.5 day / month12
month / year=165,000-231000
inch / year
188,100~260,700
inch / year
188,100~260,700
inch / year
44

Complex fitting-up
& welding area
Pipepost
treatment area
Total
Electric welder3
35~45inch / person / day2

person27.5 day / month12
month / year =23100-29700
inch / year
Electric welder1
10

Electric welder6
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
45

XIII
No.
Production Line Equipment Configure List

Name of
equipment
Item No
application
qty
unit
performance
1. Piping Detail Design And Management SoftwarePiping Detail Design Software System
And Piping Prefabrication Process Management Software System
1.1
Piping Detail
Design
Software System
Fabrication Process
1.2
Management
Software System
PDSOFT
3DPiping
IDF
interface
module
PDSOFT
SPFMS
V1.0
set
Optional
V1.0
pcs
set
V1.5
Optional
juncti
on
2Pipe Cutting And Beveling System(Pipe Cutting & Beveling Machining System And Pipe
Fittings Polishing System)
Production line-1: S.S Automatic Pipe Spool Fabrication Production Line
2.1
High Speed Pipe

Cutting & Beveling
Machine
2.2
Pipe Conveying
System For
Cutting& Beveling
Machine
2.2
Pipe Cross
Conveying System
For Cutting &
Beveling Machine
FPCBM-12Aa
2 inch-12 inch
set
2.4
Length-Measuring
System
Pipe Cutting And
Beveling Station
Frame
Wall thick18mm
Feed in and feed
PLTPS-16C2
2 inch-16 inch
set
out roller, convey

by electric and PLC
control
Up and down
PHLTS-16A2
2 inch-16 inch
set
conveying pipe to
the roller conveyor
to the machine
Be equip for cutting &
Pipe Cutting
2.3
PLC Control
PCMLS-16A
2 inch-16 inch
set
beveling machine for

length measuring
cutting. PLC control
Adopt finalized
2 inch-16 inch
product directly ,the

user prepare
themselves
Adopt finalized
2.5
Plasma Cutting
Machine
2 inch-16 inch
set
product directly,
the user prepare
themselves
46

Production line-2: C.S Automatic Pipe Spool Fabrication Production Line
2.6
2.7
Roller Bench Type

CNC Pipe Flame/
Plasma Beveling &
Cutting Machine
Pipe Conveying
System For Plasma
Beveling & Cutting
Machine
Flame and Plasma

cutting and CNC
BPPBM-24A
4 inch-24 inch
set
1-18MM (plasma)
3-45MM (flame)
Feed in and feed out
PLTPS-24D2
2 inch-24 inch
set
End Beveling
Machine
Compound bevel
FPEBM-24Aa
4 inch-24 inch
set
, , and
dual V, 5-180mm thk
Feed in and out roller,
Pipe Conveying
System For Pipe
End Beveling
Machine
PLTPS-24B2
2.10
SemiAutomatic
Flame Cutting
Machine
MPFBM-40A
2.11
Pipe Cutting And

Beveling Station
Frame
2.9
roller, conveying by
electric
High Speed Pipe

2.8
Control For V bevel.
conveying by
2 inch-24 inch
set
electrical and with

lifting system and turn
around device
4 inch
Set
auxiliary cutting
equipment
Adopt finalized
2 inch-24 inch

user prepare
themselves
3Pipe Fitting-Up And Welding SystemPipe Simple Fitting-Up Welding System And Pipe
Complex Fitting-Up Welding SystemFor Both Of S.S And C.S Production Line
3.1
3.2
3.3
3.4
Pipe Fabrication
Fast Fitting-Up
Machine
PPFUM-16A1
3 inch-16 inch
set
PPFUM-24A1
6 inch-24 inch
set
Pipe Fabrication
Assembled
Carriage
PPFUS-16A
2 inch-16 inch
1
2
pcs
PPFUS-24A
6 inch-24 inch
1
2
pcs
2 inch-24 inch
set
PPAWM-24Aa
3.5
3.6
3.7
Pipe Automatic
Welding Machine
(FCAW/GMAW)
PPAWM-24Ab
(SAW)
With one fit up head

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
Manual
Welding/Argon-Arc
Welding Machine
set
root pass, fill in, cap

welding
Adopt finalized
set

user prepare
47

themselves
Adopt finalized
STT Semi
Automatic Welding
Machine
Lincoln
3.9
Simple Fitting-Up
Welding Station
Pipe Racks
2 inch-24 inch
3.10
Complex Fitting-Up
Welding Station
Pipe Racks
2 inch-24 inch
3.8
set
product directly, the

user prepare
themselves
Provide drawing, the
user self-making
Provide drawing, the

user self-making
4Pipe Or Pipe Spools Conveying System
4.1
Pipe Fabrication
Light Rail Conveying
System
4.2
Pipe Fabrication
Heavy Rail
Conveying System
4.3
PPLTS-01T
PPHTS-10T
1T
set
Optional
10T
set
Optional
5 ton
set
Adopt finalized
Overhead Crane
10 Ton
user prepare
set
themselves
Adopt finalized
4.4
L Crane
5 ton
set

user prepare
themselves
XIV
Institutions & Staffing
1. Piping prefabrication factory institutions

Setup
always
belong to
Project
Department
leaders
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 planningin 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 stationtesting workstationfinished
products workstationhoisting with crane workstation
Material workstation take charge of pipe material stacking areapipe
fittings material stacking area taskapplication workstation take
charge of pipe painting area taskcutting workstation take charge of
pipe fittings welding polishing area and pipe cutting area tasksimple
fitting-up & welding workstation take charge of simple fitting-up
welding area taskcomplex workstation take charge of complex
fitting-up welding area taskfinished product workstation take charge
of pipe post treatment area and pipe spools finished product
stacking area taskhoisting with crane workstation take charge of
whole conveying system
2. Piping Prefabrication Factory Staffing
Account
No.
Proposed Posts
Factory Director
Requirements
Engineer Or
Technician
Peak
Time
Basic
Configurat
ion
Production Vice Director Senior Engineer
Technical Vice Director
Detail Design Engineer
Engineer
Assistant
Engineer
Management Software
Senior High
Operator
School
Technician
Engineer
Quality Inspector
Material Planner
Engineer/Senior
Worker
Engineer/Assista
nt Engineer
Remarks
Worked as a piping
Construction vice
captain
Worked as a Piping
technician
49

Senior High
Material Keeper
10
NDT Engineer
Engineer
11
Beveling Machine
Operator
Junior High
12
Plasma Cutting Machine

Operator
Senior High
School
School
School
High Speed Cutting &

13
Junior High
Beveling Machine
Operator
School
worker
worker
worker
1/3with Some
Experience,
14
Cutting Worker
Others Are
Trained Quickly
From Worker
1/3with Some
15
Experience,
Piping Assembled
Worker
Others Are
40
33
Trained Quickly
From Worker
Complex fitting-up
welding segment
with some
experienced workers
1/3with Some
Experience
16
Argon Root Welder
Others Are
Trained Quickly
From Worker
Experienced
17
Electrode Welding
All-Round Welder
Root Pass +
Cap Welding
18
Automatic Welding
Operator
19
Crane Driver
20
NDT Tester
21
Equipment Maintainer
Total
XV
Junior High
School
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
Before piping prefabrication factory workingyour should arrange
50

specialist to drawing up detail piping prefabrication work procedure

Piping
prefabrication
work
procedure
should
include
piping
prefabrication process main working procedurelike

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 trainingthe 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
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.
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
52

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
53

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
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

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

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.
57

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SHANGHAI QIANSHAN PIPING TECHNOLOGY CO., LTD.

FIXED TYPE PIPING FABRICATION

The Most Innovative Manufacturer Of

PDF "pdfFactory Pro" www.fineprint.cn

Pipe Prefabrication Overall Program

Pipe Prefabrication Process Flow

PDsoft Piping Prefabrication Detail Design Software

Piping Prefabrication Process Management Software

Pipe Beveling Machining System

Pipe Fittings Beveling & Polishing System

Pipe Spools Simple Fitting-Up Welding System

Pipe Spools Complex Fitting-Up Welding System

NDT (Non Destructive Testing) Piping System

Pipe Conveying System

Piping Prefabrication Production Capacity Estimation

Production Line Equipment Configure List

Institutions & Staffing

Procedures Programming & Staff Training

PDF "pdfFactory Pro" www.fineprint.cn

PDF "pdfFactory Pro" www.fineprint.cn

management software system

PDF "pdfFactory Pro" www.fineprint.cn

PDF "pdfFactory Pro" www.fineprint.cn

PDF "pdfFactory Pro" www.fineprint.cn

II Piping Prefabrication Overall Program

PDF "pdfFactory Pro" www.fineprint.cn

& welding station

III Piping Prefabrication Process Flow

PDF "pdfFactory Pro" www.fineprint.cn

controller finished products workstationspool piece post treatment station

IV Piping Detail Design Software System

PDF "pdfFactory Pro" www.fineprint.cn

installation: it has disadvantage of illogical subsection and lacking of relevant

PDF "pdfFactory Pro" www.fineprint.cn

PDF "pdfFactory Pro" www.fineprint.cn

PDF "pdfFactory Pro" www.fineprint.cn

PDF "pdfFactory Pro" www.fineprint.cn

V Prefabrication Process Management System

By using PDSOFT Piping Prefabrication & Installation Management Software joint

PDF "pdfFactory Pro" www.fineprint.cn

2. The software is developed by strong joint, so it is powerful and practical. Its

PDF "pdfFactory Pro" www.fineprint.cn

PDF "pdfFactory Pro" www.fineprint.cn

PDF "pdfFactory Pro" www.fineprint.cn

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

PDF "pdfFactory Pro" www.fineprint.cn

PDF "pdfFactory Pro" www.fineprint.cn

VI Piping Cutting & Beveling Machining System

PDF "pdfFactory Pro" www.fineprint.cn

using.(suit for diameter DN300mm)

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PDF "pdfFactory Pro" www.fineprint.cn

PDF "pdfFactory Pro" www.fineprint.cn

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PDF "pdfFactory Pro" www.fineprint.cn

above pipe flame/plasma cutting machine.

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PDF "pdfFactory Pro" www.fineprint.cn

7. Semi-automatic flame cutting machine bevel machining technology

VII Pipe Fittings Beveling and Polishing System

Pipe Spools Simple Fitting-Up Welding System

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