First lift successful! Guangxi Hengyi’s 1.2 million-ton caprolactam-polyamide project has fully entered the equipment installation phase
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On April 9, the ceremony for lifting the largest equipment for the 1.2 million-ton annual production capacity of caprolactam-polyamide integrated production facility and related facilities at Guangxi Hengyi New Materials Co., Ltd. was successfully held. Under the joint witness of company leadership and all participating units, the shift gas scrubber for the hydrogen-ammonia project was successfully lifted for the first time, marking the official start of equipment installation and process piping work. This event signifies that the project construction has entered a critical phase focused on actual equipment installation. At 9:17 a.m., upon the commander’s command, firecrackers went off and fireworks were set off at the site. The 86-meter-long, 676-ton gas scrubbing tower for the hydrogen-ammonia project was slowly lifted and moved steadily until it was accurately placed in position; the entire process took about 2 hours. Thanks to the joint efforts of the on-site staff, the entire lifting process was carried out smoothly and in an orderly manner, with all safety measures and management procedures properly implemented. The shift gas scrubber of the hydrogen-ammonia project is the heaviest piece of equipment in the entire plant; the successful lifting of this unit has laid a solid foundation for the subsequent installation of other equipment. 01. Comprehensive planning and repeated simulations: The large-scale equipment lifting project at Guangxi Hengyi’s factory involves 105 pieces of equipment, with the lifting process needing to be completed within 4 months. Seventeen of these devices are lifted using 4000T crawler cranes, accounting for 16% of the total; the net weight of each individual device ranges from 300 to 700 tons ； There are 25 units equipped with 800T crawler cranes as the main lifting equipment, accounting for 24%; the net weight of each such unit ranges from 100 to 300 tons ； There are 63 pieces of equipment that use crawler cranes or truck cranes with a capacity of 400T or less as the main lifting equipment; the net weight of each such piece of equipment is around 100 tons, accounting for 60% of the total. Taking large-scale lifting as its core focus, Guangxi Hengyi began formulating plans for the lifting of large-scale equipment for key installations such as hydrogen ammonia, **, and hydrogen peroxide as early as half a year ago. A thorough lifting plan is developed for each piece of equipment, covering aspects such as the lifting scheme, arrival of the equipment, routes both inside and outside the factory, road grading, construction allowances, as well as the preparation of pipelines attached to the tower. Led by the Engineering Department, a special team for planning and implementing the heavy lifting plan was formed in collaboration with the Equipment Department, Safety and Environment Department, Process Workshop, construction unit, shipping unit, supervision unit, and the procurement department of the engineering company. Regular weekly meetings were held to address the key challenges and difficulties in process control related to the safety, quality, cost, and timeline of heavy lifting operations.
On January 24, 2024, the \"Overall Construction Technical Plan for the Lifting of Large-scale Equipment for the 1.2 million tons per year caprolactam-polyamide integrated production project in Guangxi Hengyi\" was approved by experts, providing technical support for the implementation of the project. Lifting large-scale equipment is a high-risk engineering activity. After the technical plan is finalized, a dedicated team responsible for the planning and execution of such lifts conducts regular tabletop simulations to clarify each person’s responsibilities. Practical drills are carried out repeatedly on-site; any issues that arise are addressed promptly, and the details of the plan are adjusted and optimized accordingly. This systematic approach ensures that all critical aspects are taken into account. 02、Arrival of equipment – Getting the equipment ready For the lifting plan for large-scale equipment to proceed in an orderly and controlled manner, it is crucial that the equipment arrives on time as scheduled. Due to their excessive length (or height), the large-scale equipment needed to be transported at night. With the support and cooperation of the relevant **departments and public institutions, each piece of such equipment arrived as scheduled: on March 8, 2024, the shift gas scrubber 33220T-001 was successfully shipped and arrived at the site on the 9th. On March 16, 2024, the CO2 separation tower 33220T-002 for the hydrogen-ammonia project was successfully shipped and arrived at the site on the 17th. On March 18, 2024, the H2S concentration tower for the hydrogen-ammonia project was successfully shipped and arrived at the site on the 19th. The series of large-scale equipment were delivered on schedule, providing the necessary conditions for continuous and efficient handling of heavy items. As the general contractor for the hydrogen-ammonia project, Sinochem Second Construction Group Co., Ltd. had its installation team work round the clock once the shift gas scrubber arrived. They raced against time to complete tasks such as the prefabrication of pipelines connected to the tower, the construction of ladder platforms, anti-corrosion and insulation work, as well as the installation of associated electrical and instrumentation equipment. Once the tower was fitted with these components, it took on a much better appearance and was ready for lifting. 03、Condition confirmed: All preparations are in place. On March 20, 2024, the 4000T crawler crane began assembly on a full scale, with its components being gradually transported to the installation site. From April 4th to 8th, the members of the special task team responsible for planning and implementing the heavy-lift lifting plan worked without rest, rushing to the site as soon as possible to thoroughly evaluate the lifting plan for the shift gas scrubber tower, review the preparations prior to the lifting operation, and handle tasks such as traffic management, control, and security measures, in order to make the final efforts for the first lift of the project. The shipping party focuses on ensuring the availability of personnel, rigging, and machinery, guarantees that the staff are qualified and that the equipment is suitable for lifting tasks, and reorganizes and emphasizes the key steps in the operation process. After half a year of careful planning, meticulous organization, and coordinated efforts by various parties, the first lifting of the modified gas scrubber has finally taken place. The successful lifting this time provides valuable experience for the subsequent handling of the remaining equipment, including assembly welding, ladder platform installation, anti-corrosion and insulation work, as well as electrical and instrumentation installations.