The cracking furnace area of the ethylene plant in Tarim’s 1.2 million tons/year Phase II ethylene project was successfully completed without any residual work

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Recently, the second phase of Huqiu Company’s Tarim ethylene project, with an annual production capacity of 1.2 million tons, reached a key milestone: the cracking furnace area of the ethylene plant was completed without any outstanding tasks, marking significant progress in the project’s construction and laying a solid foundation for its timely commissioning. As the \"heart\" of the ethylene plant, the cracking furnace area is responsible for converting raw materials into key products such as ethylene and propylene; the quality and progress of its construction directly affect the operational efficiency and safety levels of the entire project. The pyrolysis furnace area, where construction without residual tasks has been achieved this time, consists of multiple large-scale pyrolysis furnaces along with associated coke cleaning systems. It involves complex process units such as high-temperature and high-pressure pipelines, special alloy equipment, and precision instruments. Factors such as high requirements for construction accuracy and the difficulty in coordinating concurrent operations make this area a \"hard-hit zone\" with a high concentration of residual tasks and frequent rectifications. Achieving construction without residual tasks in this area represents an extreme test of the project’s management system, technical capabilities, and coordination skills. To achieve this goal, the project team has implemented a \"full-cycle, meticulous\" management approach since the project commenced. A \"tail-free\" construction support system covering the entire life cycle has been established. During the preliminary preparation phase, various specialties carried out collaborative reviews of 3D models to address issues such as pipeline collisions and equipment interface discrepancies in advance. More than 12 construction plans were optimized as a result, thereby reducing potential problems from the outset. During the construction process, the project team innovatively adopted a \"modular prefabrication + precise on-site lifting\" technique, assembling large components such as the radiation section and convection section of the pyrolyzer on the ground. This not only increased construction efficiency by over 40% but also ensured the precision of these components through strict quality control, thereby significantly reducing the need for on-site corrections. The convection section of the pyrolysis furnace, the steel structure of the furnace body, and certain process pipelines are deeply modularly prefabricated on the ground, after which they are installed using large-scale lifting equipment in a \"building-block\" manner. This approach significantly reduces the need for work at heights and on-site welding, thereby improving quality control and construction efficiency. For critical equipment, the project department implements \"special expedited procurement\"; for high-grade pipes such as P91, \"order-based\" production management is adopted to ensure that materials are available as needed, thereby preventing process delays due to missing components or chaos caused by inventory buildup. For key aspects such as stress control in high-temperature pipelines and special welding processes, the project team established a \"technical problem-solving team\" to develop specific welding process evaluations. A dual-entry system based on both certification and practical skill assessment was implemented for welders; in total, over 340,000 inches of special welds were inspected, with a first-pass success rate of 98.3%. At the same time, a \"grid-based\" quality supervision system is implemented, with the furnace area divided into 7 responsibility grids. Dedicated quality inspectors and safety officers are assigned to these grids, and an acceptance mechanism that requires quality inspection to be completed after each work stage is applied, ensuring that \"construction is carried out in one area, inspected in the same area, and closed off in the same area.\" During the phase of rushing to complete remaining tasks, the project team launched a special campaign to eliminate these remaining tasks. It established a three-list system comprising a list of problems, a list of responsibilities, and a list of deadlines; held daily meetings to update a dynamic list of remaining tasks, and implemented a system of completing tasks on a daily basis. A “Pending Items Management Dashboard” is set up in the on-site office area to display in real time the total number of pending items, the number that have been resolved, and any key challenges. Encourage the elimination of minor issues as they arise, by implementing \"team self-inspections\" and \"departmental inspections\" to ensure that work is completed, materials are used up, and the work area is cleaned up in real time. Through the continuous efforts of all team members, all construction tasks in the pyrolysis furnace area passed the inspection in one go, with no outstanding items requiring correction; thus, the goal of having a project without residual issues was achieved 60 days ahead of the original schedule. The achievement of tail-end construction-free work in the cracking furnace area marks a crucial shift in project construction from \"large-scale construction\" to \"meticulous finalization\". Next, the project team will focus on tasks such as purging and commissioning, strictly controlling safety and quality to ensure the project is put into operation on schedule.