1. Shorten the installation duration
Due to the factory-based processing and preparation, the on-site installation workload has been significantly reduced. The assembly rate of pipeline butt welds can reach 50%, the assembly rate of fillet welds on nozzle stubs can exceed 90%, and 100% of lifting blocks and clamping blocks are welded. Additionally, 100% of pipeline bends and pipe end grooves are processed. Due to the reduction in on-site installation workload, the installation duration for the four major pipelines in power stations has been shortened from 5-6 months without preparation to 2 months or even shorter (for example, the installation of the four major pipelines for the 2*300MW Unit 1 in Qujing took only 35 days).
2. Save on pipe materials
Factory-based processing and formulation, through computer-aided design (CAD) optimization and material selection, have improved the utilization rate of tubing. The procurement margin for tubing has been reduced from over 10% for non-formulated tubing to 3-5% for formulated tubing, thereby reducing waste and lowering material costs.
3. Improve quality
Compared to on-site open-air construction, factory production has changed working conditions, facilitating specialization and large-scale production. The use of specialized advanced processing equipment and methods is conducive to controlling the quality of welding and inspection, and allows for overall post-weld heat treatment, thereby improving the quality of pipelines.
4. Save construction costs
Factory-based prefabrication can significantly reduce or even eliminate the need for beveling machines, milling machines, and other tools used for on-site pipeline fabrication. This not only reduces the required space but also cuts down on costs associated with the handling, maintenance, and repair of these tools, as well as the number of temporary platforms and buildings required, ultimately leading to savings in construction expenses.
5. Reduce the number of pipe blowing operations
Factory-based processing and preparation employ processes such as sandblasting (shot blasting) and acid cleaning, which can completely remove oxide scales, rust, and other impurities from the interior of pipelines. This can eliminate the need for chemical cleaning of individual systems before the boiler after installation, significantly reducing the number of steam pipe flushing operations and saving on pipe blowing costs. 6. Improve design
Factory-based processing and formulation optimize the original design through CAD technology, which can further improve the design work. Additionally, it can easily correct the dimensional deviation issues of pipe fittings, valves, etc. through dimensional adjustments, bringing great convenience to construction.
7. Reduce project cost
By adopting factory-based formulation, the construction cost can be significantly reduced.