【Haichuan Modularization】Modular installation of the steel structure framework for Guangdong Petrochemical’s 800,000 tons/year full-density polyethylene plant
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On September 13, 2021, the third-layer framework of the first and second reaction units in Guangdong Petrochemical’s 800,000 tons per year full-density polyethylene plant was hoisted into place; this represents the second batch of steel structure frameworks to be assembled on site as part of this project. The reaction frames for the first and second lines of Guangdong Petrochemical’s 800,000 tons per year full-density polyethylene plant weigh 443 tons each; each module is 14.58 meters long, 3 meters wide, 19.5 meters high, and weighs 49.6 tons. Due to the previous reactor hoisting, some foundations underground in the reaction unit still cannot be constructed. How to quickly complete the steel structure once the large components are in place, thereby providing a working area for other trades, has become a key focus for the project team’s subsequent construction efforts. To accelerate the construction progress, after discussion and consideration, the project team decided to prefabricate the steel structure of the third floor, as well as ladders, platforms, guardrails, etc., in a modular manner on the ground simultaneously with the installation of the second-floor structure of the reaction frame, and to carry out the construction using a holistic lifting method. By enabling simultaneous construction of the secondary and tertiary steel structures, this approach reduced the construction period by about 20 days. To ensure that the materials meet the requirements of on-site construction, the project department has specifically prepared a material requirement plan. To address the issues of limited construction space and difficulties in storing materials, the project team held meetings between the general contractor and the steel structure manufacturers to discuss the production status of the materials and the timing required for their delivery on site. This ensured that materials were supplied on time and as needed, allowing them to be used promptly without excessive accumulation or occupation of space, while still meeting the construction requirements.
To accelerate the construction progress, the project team organized the work crews to assemble the steel structure during the day and work overtime to weld at night. To ensure safety during night operations, in addition to the personnel on duty at night, one Party member from the project team stays behind on a daily basis to oversee safe working practices. This has created a positive working environment and enhanced the awareness of self-management regarding safety at the site. After the modules are prefabricated, safety engineers conduct a final inspection of the safety conditions on site, as well as the safety procedures regarding equipment and workers. Meanwhile, the Technology and Quality Department organizes a joint inspection prior to the lifting of the framework. Once safety and quality inspections are passed, the module is officially confirmed to be ready for lifting. On September 6, with the arrival of the 600-ton crane, the modular lifting of the third-floor framework on the reaction site officially began. The various departments of the project team assigned personnel to supervise the lifting process throughout its entirety, in order to ensure the quality and safety of the construction. By 5 p.m. on September 13, the framework modules for the third floor of both Line 1 and Line 2 had been lifted into place. This is the second time that the HDPE project team has achieved modular lifting of steel structures, following the implementation of the raw material refinement framework. The team will actively adhere to the “six modernizations” standards, pool ideas, optimize plans, and strive to improve quality and efficiency in order to create high-quality projects.
Guangdong Petrochemical’s 800,000 tons per year full-density polyethylene plant adopts the patented gas-phase fluidized bed polyethylene production technology from the American company UNIVATION. It is equipped with two production lines, operates for 8,000 hours per year, and has an operational flexibility range of 50% to 110%. The use of condensation-based operation techniques enables a significant increase in production capacity. This device utilizes three catalyst systems: titanium-based, chromium-based, and metallocene-based, enabling the production of polyethylene products with high, medium, and low densities. These products are suitable for various applications such as film production, injection molding, hollow products, drawn products, and pipes. A total of 102 grades have been introduced, including 15 typical grades: 4 LLDPE film grades, 2 MCN film grades, 1 LLDPE injection molding grade, 1 HDPE injection molding grade, 1 monofilament grade, 3 HDPE blow molding grades, 2 HDPE film grades, and 1 HDPE pipe grade. It is the polyethylene production plant in China with the widest range of grades, the most extensive application, and the highest annual production capacity for this process. Image: The First Branch of Jilin Chemical Construction, along with the Full-Density Polyethylene Project Department of Guangdong Petrochemical, is responsible for the construction of this facility. The main construction tasks include: 231 pieces of equipment, 200,000 inches of process piping to be welded, and 3,600 tons of steel structures; the total area covered by the construction is 58,000 square meters. Construction of the project began on May 1, 2021; it was completed on June 27, 2022, with delivery taking place on February 25, 2023. The entire process took nearly 22 months, during which 987 workers were employed at the peak stage.