【In-depth Discussion on Modular Installation of Haichuan Systems】Construction Case – Modular Installation of 6×800,000 Nm3/h Air Separation Cryogenic Units at Hengli Petrochemical
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Hengli Petrochemical | Successful lifting of main cooling box and argon cooling box for 6×80,000 Nm3/h oxygen production project. News from May 17 – Recently, the 6×80,000 Nm3/h oxygen production project for Dalian Hengli Petrochemical’s air separation unit, constructed by Shanghai 20th Metallurgical Construction Co., Ltd., saw the successful lifting of the 11th main cooling box and argon cooling box. This marks the beginning of the installation of large-scale integrated cooling boxes in China, and it also signifies significant progress in the research and development of such large-scale integrated cooling systems in the country. As the first set of 6×80,000 Nm3/h integrated skid-mounted cryogenic containers installed in China to date, the No. 1 air separation cryogenic container consists of one main cryogenic container and one argon cryogenic container. The main cryogenic container is 7.8 meters long, 7.5 meters wide, and 60 meters high, with a net weight of 480 tons ； The argon cryostat is 7.1 meters long, 6 meters wide, and 5.9 meters high, with a net weight of 345 tons.
Faced with construction challenges such as the large weight and height of the main and argon-cooled chambers, limited working space, high uncertainty due to the monsoon climate conditions on site, and difficulties in lifting and transportation, the 20th Metallurgical Construction Department held a special meeting to develop an advanced and reasonable lifting plan. It was decided to use a two-crane lifting method, with a CC8800_1_Twin type 3200-ton crawler crane combined with a QUY 500-ton crawler crane for assisting in the lifting process, and specialized modular lifting equipment was designed to effectively reduce the risks associated with lifting operations. Through thorough preparation and efficient organization, the lifting operation was completed successfully.
The hydrogen production facility using coal as a feedstock has a capacity of 500,000 Nm3/h (including the air separation unit), and it is capable of producing 240,000 tons of pure hydrogen per year. German company Linde’s technology, along with domestic technologies, is used in this project. This project has been included in the “Opinions of the State Council on Several Key Policy Measures to Support the Revitalization of the Northeast Region” as well as in the “Three-Year Rolling Implementation Plan for Revitalizing Old Industrial Areas such as the Northeast Region (2016–2018)”. Advanced international process technologies from companies such as Chevron, Lummus, GTC, Grace, Topsoe, and Axens are utilized in this facility. Installation is scheduled to be completed by the end of July 2018, followed by commissioning efforts; the goal is to start operations by October 2018 and reach full capacity in the first quarter of 2019. It is expected to become the world-class petrochemical industrial park to be built among the **seven major petrochemical industry bases.
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On November 27, six low-pressure plate heat exchangers for Unit 11 of the cold box in the 6x800,000 cubic meter air separation unit project at Dalian Hengli Petrochemical, undertaken by the Installation Engineering Branch, were lifted into place.
The heat exchanger is the core equipment inside the cold box; it weighs 15 tons and is 5 meters long, and it is located within a plate-type cold box with a closed height of 12 meters on all sides. The site is narrow, and since the project is located near the sea, strong winds pose significant difficulties for lifting operations. To ensure the smooth lifting of the plate heat exchanger, the project team made thorough preparations and careful plans, carrying out all necessary preparations prior to construction. By using a 150-ton crawler crane and a 50-ton wheeled crane together, the lifting was completed successfully, earning high praise from the construction owner, the supervision agency, and the client.
Hengli Petrochemical (Dalian) Refining & Chemical Co., Ltd. and Linde Engineering (Hangzhou) Co., Ltd. signed EP contracts for six sets of 80,000-class air separation units and one set of carbon monoxide cryogenic tanks. The contracts for the first phase’s three sets of air separation units were signed in October 2014, and preliminary design work was carried out within Linde Engineering, which laid a positive foundation for the subsequent implementation of the entire project. The Phase 1 and Phase 2 contracts came into effect on February 7, 2017. Thanks to the preliminary design carried out in the early stages of the project, Linde Engineering was able to manufacture the series of integrated cryogenic tanks in the shortest possible time and deliver them to the site one after another. Six sets of ultra-large air separation units with an capacity of 80,000 units each utilize gasification technology to produce syngas for the downstream oil refining, aromatics, chemical manufacturing, and ethylene production facilities with a capacity of 20 million tons per year; meanwhile, by-products such as methanol and acetic acid are also generated.
The large amount of on-site welding creates a high demand for welders ----------------------------------------- @Cleaner @LQ198619 @RedLee_ZZHI ------------------------------------------------------- In a competition among more than 300 welders in the air separation unit area, Wu Bangxu, a welder from the installation company, stood out as the best performer. In the fourth quarter of 2017, he took 226 photographs of aluminum alloy pipes that were all found to be qualified, resulting in a 100% first-pass success rate； In the first quarter of 2018, a total of 922 radiographs were taken for welded aluminum alloy pipes; 9 pipes required rework, resulting in a first-pass qualification rate of 99.02%, which represented an excellent outcome. The welder was recognized as an outstanding welder for two consecutive quarters. It brought honor to Sichuan Airlines and won unanimous recognition from the owner, Zhongan, and the supervisor. To ensure the quality of construction work, the installation department provided extremely rigorous operational training and practical tests for the 46 welders who arrived at the site one after another. Through several batches of operational training and practical exams, 46 welders passed the tests one after another and obtained the welder certification for the 3×70,000 Nm3/h air separation cryogenic unit project, issued by the Zhongan Project Department.
There’s a shortage of welders this year; there really is a shortage. Automatic welding is now widely used in prefabrication workshops, but there is still a shortage of welders.