【Ten Years of Rapid Development in Chemical Equipment】1612–2024: Integrated Installation of 136-meter-tall, complex-shaped, heavy-duty steel structure modules for petrochemical plants

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Happy May Day 2024! Safety first. **********************[A Decade of Progress in Chemical Processing Equipment] Continuous updates and summaries available; feel free to join the discussions at https://bbs.hcbbs.com/thread-3576046-1-1.html (Source: Haichuan Chemical Forum) ***************** The reforming unit of Zhejiang Petrochemical’s 40 million tons per year integrated refining and chemical processing project is located on Yushan Island in Zhoushan City, Zhejiang Province. Units 1# and 2#, each with a capacity of 3.8 million tons per year, are currently the largest single reforming units of their kind in China. The steel structural frameworks for areas 2102 and 2103 in these units are combined into one structure, reaching a height of 136 meters and weighing a total of 3,200 tons; these frameworks are crucial for the construction of the entire unit. This research project focuses on how to achieve safe and efficient construction under the constraints associated with island construction in engineering projects – such as high quality requirements, large workload – as well as considering the challenges posed by ultra-high-rise, irregularly shaped, heavy H-shaped steel structures that weigh over 3,000 tons. Focusing on the modular construction of super-tall large-scale steel structures for petrochemical plants (with a height of 136 meters and a weight of over 3,000 tons), the steel structure of the foundation section is installed using single beams and columns, while the upper part is constructed through a combination of prefabrication in sections, assembly of those sections, and installation of the complete framework ； The construction area of super-tall large-scale steel structures is divided up; BIM technology is used to allocate the various modules appropriately, with these modules being prefabricated in different locations before being integrated on site through coordination among various specialties. This approach **reduces the amount of work that needs to be done at great heights and ensures better welding quality** ； Due to the uneven stress distribution over large areas of the tidal flats at the construction site on the island, more than 60 concrete load-bearing platform bases were constructed on-site, enabling modular assembly of the steel structure. This approach helps to reduce deformation defects that occur during the manufacturing and storage of the steel structure modules, thereby shortening the construction period ； The optimal lifting plan is selected in conjunction with lifting simulations. This technology has been applied to Zhejiang Petrochemical’s 40 million tons per year integrated refining and chemical processing project, enabling the on-site assembly of super-tall steel structures as well as their lifting in sections or frames. This approach significantly improves work efficiency, reduces labor costs, and enhances the overall quality of the construction work. It reduces the frequency of work at heights, thereby lowering the safety risks associated with such work, and provides more reliable safeguards for the safety of workers. With a prefabrication and assembly level of 60–80%, the project duration is reduced by 42.7%; the costs related to safety measures for work at heights are cut by 40%, while labor costs are reduced by 39.4%. By reducing the number of lifting operations at great heights, the number of shifts required for large machinery is significantly decreased, resulting in a 38.3% savings on machinery rental costs compared to traditional lifting methods. It has achieved good economic and social benefits for the project construction, and has received unanimous praise from all relevant parties. One provincial-level construction method in Zhejiang Province was developed, and the two patents independently created by the company were put into practical use through the transformation of patent innovations.