【In-depth Discussion on Modular Installation of HaiChuan Systems】Modular installation of the 140-meter tall, 1,000-ton torch for the ZhongAn United Coal Chemicals project
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On November 22, it was reported from the construction site of the Zhongan United Coal Chemical Project, which is currently under construction, that the tallest structure at the site – the flare tower – built by Sinopec Fourth Construction Company No. 2 – was successfully lifted into place after the workers involved worked together to overcome various challenges, using a modular construction method. It is reported that the flare tower of the Zhongan United Coal Chemical Project is 140 meters tall and weighs 1,000 tons in total. It is composed of around 800 steel pipes of specifications ranging from Φ200 to Φ500, which are connected together to form this flare tower; it is the tallest structure in the Zhongan Coal Chemical complex. To ensure the safe, high-quality, and efficient assembly of the torch tower structure and to achieve the goal of modular installation, the project team from Sijian No.2 Company carefully planned the site layout and optimized the construction plan based on the conditions of the site and the arrival of materials. In light of the safety risks associated with working at great heights, the project held special meetings to identify such risks and develop strategies for their mitigation, while also establishing standardized requirements for the erection process ； Conduct physical examinations for workers working at heights ； Provide training on the precautions to be taken when personnel work at heights ； Assign a dedicated safety officer to oversee things and ensure that safety measures are properly implemented. At the same time, the construction plan was optimized based on the characteristics of the tower; the tower was divided into seven sections, which were assembled modularly on the ground to form a frame, after which they were lifted and connected section by section to create the 140-meter-tall entire torch tower. The first section of the frame is lifted and assembled on the foundation to ensure a stable base for the tower; thereafter, the six modular tower sections that have been assembled on the ground are installed one after another, from bottom to top.
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Through proper planning and meticulous organization, all employees involved in the project overcame difficulties, carried out construction strictly in accordance with standards and procedures, and created the conditions necessary for installing the torch tower. Especially since it is currently the rainy season in the Huainan area of Anhui, the construction of the tower at the Torch site of the Zhongan project, which is being built by Sijian, has not been affected by the bad weather. On November 15th, after intense preparation, the employees involved in the project gave up their lunch breaks, and the lifting operations officially began at 12:30 p.m. that day. As the 1,000-ton crane lifted it slowly, the second section of the torch’s frame tower, which is 14 meters high, 24 meters wide and weighs 130 tons, was raised. With the crane raising its boom and jib, the second section of the frame was placed firmly on top of the first section’s frame at a height of 14 meters. At this time, the workers stationed at a height of 14 meters worked in teams, fully equipped, to assemble and connect the legs of the torch tower at the 12 connection points. After more than 2 hours of interface alignment and connection, the first section and the second section of the tower were successfully joined together; at this point the height of the tower reached 28 meters, and the installation of the initial frame of the tower using the thousand-ton crane was completed successfully.
According to Sinopec News Network (Yu Yang), on December 23, the installation of the heaviest steel structure module for the main corridor of the new Fengming PTA plant with an annual production capacity of 2.2 million tons in the Jiaxing project site operated by Shijian was completed. Taking into account factors such as the arrival of steel structure materials, the actual conditions of the site, the timing of crane deployment, and the space required by the cranes, the project team divided the main corridor into 6 modules. All of these modules were lifted using 650-ton crawler cranes. The fifth module to be lifted was the heaviest one, with a lifting weight of 232 tons; it measured 19 meters in length, 17 meters in width, and 17 meters in height, and its intended installation height was 19.3 meters. There are 10 pieces of equipment on the top of the main corridor. When formulating the plan, the project team needs to determine the methods for handling the construction site for these modules, the ways to support the steel structure columns, and the locations where the modules will be placed; in addition, it is also necessary to identify the components that need to be reserved for the lifting of the equipment. To ensure the continuity of module construction, the project team actively coordinates with the owner and manufacturers before module assembly and during the construction process to determine the timing and sequence of material delivery, and promptly arranges the necessary manpower and equipment on site, striving to resolve any issues that arise on the same day they occur. During the assembly process, as the overall weight of the module increased, to prevent localized settlement, the project team placed steel plates with a thickness of 2 cm under each column foot of the module in order to increase the load-bearing area. They also regularly measured the settlement of each column foot and made adjustments promptly if any issues arose, thereby ensuring the stability and safety of the module. To further reduce safety risks associated with working at heights, this project increased the prefabrication depth of all modules, completing on the ground all the processes that could be done there, such as module pre-assembly, bolt tightening, welding, anti-corrosion painting, and railing installation. Due to the asymmetric structure of the module’s center of gravity, the center of gravity does not coincide with the centroid, and determining the offset of the center of gravity becomes an important challenge. During the project planning phase and in the early stages of construction, the project team organized several special meetings with relevant personnel ； During the module assembly process, technicians checked the weight of the modules multiple times, measured their verticality, the distance between axes, and diagonal dimensions, continuously refining the construction plan to ensure that the modules could be properly positioned during lifting. It is understood that the last module of the main corridor was assembled on December 16, and its lifting will be completed this month. The 6 module pairs took a total of 35 working days (of which 12 were rainy days), achieving half the efficiency of traditional construction methods.
I’m not sure if there are any photos of the lifting process on site; it’s hard to understand many details just by reading the text.
Is it the Pinghu, Dushan project? Could you introduce the PTA process?
This post was last edited by Desert Fish on 2018-12-27 at 10:52