【Haichuan’s Best Practices】Using universal transport vehicles to install the compressor tube bank in high-pressure polyethylene systems

Thread Content

Problem: When installing tube bundles in the compressor unit factory shed, limited working space is encountered. Construction workers need to use large cranes and chain hoists in order to transport the pipe bundles to their installation locations; during this process, there is a risk of damaging the delicate compression unit equipment. In this way, only 2 tube bundles can be installed per day, which results in low efficiency and high labor intensity. Innovation: The employees involved in the Zhejiang Petrochemical Project team of Shijian Company focused on the safety, stability, and flexibility of tube bundle transportation, and developed an omnidirectional transport vehicle that is easy to manufacture, convenient to operate, and safe and reliable for use in the transportation and installation of tube bundles. The effect is that the universal transport vehicle significantly improves the efficiency of transporting and installing the tube bundles of compression units, effectively reducing the workload on construction workers. The original processing time of 16 days was reduced to just 4 days, saving nearly 300,000 yuan in crane costs, while also eliminating the potential risk of equipment damage. On July 24th, as night fell, on Yushan Island in Zhoushan, Zhejiang, the interior of the compressor plant for Zhejiang Petrochemical’s 300,000 tons per year high-pressure polyethylene production facility, which was constructed by Shijian Company, was filled with a hot and humid atmosphere. “A single tube bundle weighs 5 tons, and the steel beams and pipelines above create a crowded layout, leaving only a narrow passage of less than 3 meters wide; as a result, large cranes are trapped there and unable to exert their full strength. ”Meng Qi, a technician from the Zhejiang Petrochemical Project Department of Shijian Company, experienced firsthand how cramped this \"chest cavity\" was while leading the construction workers in preparing the pipe bundles. “This ‘steel needle’ is 17 meters long, yet the gap left for us in the shed is not even as wide as the needle’s eye. ”said construction manager Dong Bo. Conventional lifting methods won’t work, and forcing it could damage the precision tube bundles. The difficulties weighed like iron shackles around Meng Qi’s throat. In the darkness, he returned to the temporary shed and began drawing sketches of various vehicles. It wasn’t until 11:30 at night that he had an idea: to abandon the aerial route and opt for a ground-based approach, by creating a specialized vehicle capable of moving nimbly through narrow gaps. The sketch of the special vehicle quickly took shape under Meng Qi’s hand. This 15-meter long and 0.8-meter wide vehicle has a sturdy I-beam as its backbone, ensuring that 17-meter-long pipe bundles can lie flat on it. 10 swivel wheels enable 360-degree smooth steering. Meng Qi gave it a name — Universal Transport Vehicle. At the same time, a hydraulic lifting mechanism is installed at the bottom of the vehicle, allowing it to simply \"lift itself\" over obstacles. The first universal transporter was born amidst the welding sparks of the early morning. Early in the morning on July 25th, the Wanxiang transporter carried the first tube bundle toward the entrance of the compressor unit factory shed. Dong Bo handled it carefully, ensuring that the tube bundle remained stable on the trailer, with the swivel wheels allowing for smooth steering. With pipelines lying across the path ahead, he touched the hydraulic switch; the vehicle rose steadily, and the pipeline bundle safely \"stepped over\" the obstacle. After the tubes are transported one by one to the inlet of the compression unit using a universal transporter, the workers carry out welding to connect the equipment inlet with the tube inlets. Throughout the entire process, the tube bundle acts like a thread, which is precisely guided by the articulated transporter through the narrow working space. “It’s just like embroidery – such a large iron piece moving smoothly and steadily along the seam! ”Dong Bo said. Called by its employees the “steel embroiderer,” this small vehicle demonstrates its prowess with a compact size that is smaller than that of regular crane components. “Installing the tube bundle with a crane took 16 days, while it was completed in just 4 days using a universal transporter, saving 300,000 yuan in costs and eliminating the risk of equipment damage. ”On July 29, after seeing all the high-quality control components installed in place, Meng Qi began to calculate the benefits.