【Major Equipment in the Chemical Equipment Industry】060 – Overall translation of a waste heat boiler with a total weight of over 3,696 tons
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The past decade has been a period of rapid development for China’s chemical industry, marked by the emergence of many new processes, products, and equipment. There has also been significant progress in China’s chemical processing equipment, which has contributed to the swift advancement of the petrochemical sector. Here, we have compiled some of the achievements and breakthroughs made by Chinese equipment manufacturers in terms of larger-scale production and greater use of domestic equipment. We invite everyone to share their insights and discuss these topics together; let’s cheer for Made in China and support the development of chemical processing equipment! *********************************** At 9:16 a.m. on August 16, 2016, upon the command of the on-site chief commander of China National Petroleum First Construction Company, at the construction site of the 3 million tons per year catalytic cracking unit in Lanzhou Petrochemical Company’s refinery, two waste heat boilers were slowly pushed forward along the prepared slides, guided by traction mechanisms. That afternoon, the two waste heat boilers were translated 28.4 meters each, sliding into place smoothly, efficiently, and precisely, marking the successful completion of the transfer of the heaviest boilers in China’s petrochemical industry!
The waste heat boiler renovation project is a key component of the maintenance work for the 3 million tons per year heavy oil catalytic cracking unit at Lanzhou Petrochemical Company’s refinery. This project involves the complete replacement of the existing two waste heat boilers (with some equipment being reused). To ensure successful completion within the maintenance period, a construction method was adopted involving the overall prefabrication of the new waste heat boiler in another location; after the old boiler was removed, the new boiler was moved as a whole to its foundation and installed in place. That is, before the shutdown of the facility, the overall installation of the two new waste heat boilers was completed in advance on the maintenance passage to the north of the old boiler ； After the plant stops operating, the old boiler is removed first, followed by the complete relocation of the new waste heat boiler to its installation location for setup. Thereafter, the remaining process pipelines, electrical instruments, and auxiliary equipment are installed, ultimately enabling the plant to resume operation.
More people are welcome to participate in the relevant discussions. Click on the blue link to access it: The 【Haichuan Equipment Guessing Game】 series is being updated continuously in 2022; all Haiyu members are encouraged to join in! https://bbs.hcbbs.com/thread-2079686-1-1.html (Source: Huahai Chuanliu – Haichuan Chemical Industry Forum) Summary post on the series 【Major Equipment in the Chemical Equipment Industry】 https://bbs.hcbbs.com/thread-3312079-1-1.html (Source: Huahai Chuanliu – Haichuan Chemical Industry Forum) Summary post discussing the components of cracking furnace equipment for 【Ethylene Cracking】 https://bbs.hcbbs.com/thread-3308724-1-1.html (Source: Huahai Chuanliu – Haichuan Chemical Industry Forum)
According to traditional construction methods, boiler replacement requires removing the old boiler in place and installing two new boilers, during which the plant must be shut down. Renowned for its achievements in producing products, developing technologies, accumulating experience, training talent, and generating profits, Lanzhou Petrochemical Company aims to find new ways to minimize the impact of maintenance work on production operations. After extensive research and planning with the company, it was ultimately decided to prefabricate the new boiler in another location and then transport it in its entirety for installation in place. This approach does not affect normal production; the transformation and replacement of the boiler can be carried out during maintenance periods, thereby ensuring that Lanzhou Petrochemical meets its annual production targets and performance indicators. However, there is no precedent in the petrochemical industry for such a large and heavy furnace to be translated over long distances. The two boilers are 45.3 meters high, 16.4 meters long, and 25.9 meters wide, with a total weight of 3,696 tons. Moving them over a distance of 28.4 meters presents a significant challenge in terms of ensuring stable movement. To overcome this issue, the company used high-strength alloy plastic slides, which not only offer excellent wear resistance but also help to significantly reduce friction. Furthermore, the central control system is used to keep the synchronization error between the two jacks at the millimeter level, ensuring that the boiler does not tilt due to uneven forces. According to Zhang Jingbiao, a senior lifting expert, currently only Yijian Company in China possesses the technology for centralized control hydraulic traction and translation, and the current levels of walking accuracy and friction coefficient are among the best in the world. .