Start A Conversation
Click here to talk with TDM Chatbot !
Click here to chat with me!
Search our website now
Related Articles
Categories
Share
Facing Similar Technical Challenges?
Discuss your facility's EPC and technical engineering needs with our team of experts. We guarantee precise, safe, and efficient execution to global standards.
A large-scale chemical industrial facility is required to have exceptional operational reliability. Routine maintenance or overhauling of the main turbine engine is a highly essential activity. This overhaul process always requires specialized lifting equipment designed with absolute safety precision. Answering this strategic need, PT Tri Daya Maxima successfully executed a lifting tools fabrication project and its feasibility certification. This heavy lifting equipment project is utilized at the facility owned by PT Asahimas Chemical (ASC).
The completion of this lifting equipment engineering project is a highly commendable technical achievement. Precision lifting equipment ensures that turbine components worth hundreds of billions will not incur damage during relocation. We successfully designed, manufactured, and rigorously tested the feasibility of these special lifting tools. This once again solidifies our company’s reputation as a highly trusted mechanical engineering specialist.
Background of the Lifting Tools Fabrication Project in Cilegon
This lifting equipment engineering project is located in a highly vital industrial area. The PT Asahimas Chemical plant facility is located at Jalan Raya Anyer-Sirih Km 122. This strategic industrial zone is situated in the Gunungsugih area, Cilegon City, Banten Province. The dense plant location demands strict discipline and highly rigorous project management.
The execution timeline for this technical engineering work was highly structured. The work officially commenced on April 6, 2023. All stages, from design to delivery, were targeted for completion by May 29, 2023. The project itself was carried out through a strategic collaborative contract with PT Wasa Mitra Engineering.
We ensured the smooth running of the project by submitting comprehensive banking instruments. We issued an Advance Payment Guarantee, Performance Bond, and an official Warranty Guarantee. After-sales protection is also guaranteed through an installation warranty period of 6 calendar months. The warranty period is valid after all installations are declared complete and fully operational. You can view our EPC track record on the Mechanical Service Portfolio page.
Safety Standards for Lifting and Transporting Equipment
Manufacturing lifting gears for turbine components carries extreme risks. Even a minor design flaw can result in fatal occupational accidents and permanent engine damage. Occupational Health and Safety (OHS) is always the core principle of our fabrication process.
Every stage of structural steel welding is supervised with a high degree of precision. We comply with all feasibility requirements for Lifting and Transporting Equipment in accordance with government regulations. This feasibility testing involves an independent third party to ensure the objectivity of the test results. You can read about lifting equipment safety standards through the Indonesian Ministry of Manpower.
Integrated Lifting Tools Fabrication Project Scope
This special tools provision project is a concrete manifestation of our integrated engineering services. The scope of work is divided into several continuous design and production stages. Here is a detailed breakdown of the fabrication stages we have completed to 100% progress:
1. Engineering Calculation and Fabrication of Turbine Blade Spreader Beam
The very first step before cutting the steel is the Engineering Calculation stage. Our engineering team calculates the center of gravity of the load with absolute accuracy. We then execute the fabrication of the lifting tools, specifically the Turbine Blade Spreader Beam.
This lifting tool is built to a massive size of 6,000 x 3,450 millimeters. Its primary function is to lift the turbine blade components in a balanced manner. This balance prevents the turbine blade components from bending when lifted by the plant crane. The steel structure welding is performed by highly experienced, Oil and Gas certified welding experts.
2. Fabrication of 18-Ton Capacity Diaphragm Nozzle Skid
The diaphragm nozzle component on a steam turbine engine is exceptionally heavy. Therefore, we manufactured 2 units of special mounting facilities, or Diaphragm Nozzle Skids. These steel mounts are designed to withstand static loads of up to 18,000 kilograms.
Thick-profile carbon steel material is used to assemble the base for these turbine components. The assembly process considers ease of access for technicians when cleaning or repairing components. The quality of the weld joints is guaranteed to be extremely strong so the mount does not collapse while supporting the turbine.
3. Fabrication of HIP Bolt Spreader Beam and Crossover Pipe Stand
Turbine engines also utilize massive High-Pressure (HIP) Bolts. We precision-manufactured 2 units of Spreader Beams for HIP Bolt Lifting. The lengths of these lifting aids are 936 millimeters and 442 millimeters, respectively.
In addition to bolt lifting tools, we also produced 1 unit of Crossover Pipe Stand Work. This supporting facility is vital to sustain the circulation pipes during the overhaul period. All equipment is crafted with a dimensional error tolerance approaching zero.
4. Fabrication of Gantry with Rail for Mobility Ease
Moving heavy components within the turbine hall is heavily restricted by space constraints. Responding to this challenge, we successfully fabricated 1 set of Gantry with Rail. This lifting structure system is designed to move horizontally using steel rail wheels.
The gantry system makes it easier for technicians to shift heavy components without having to use a large crane. The steel rails are installed precisely so that the load wheels move smoothly and without obstruction. This facility significantly saves time during the engine dismantling and assembly process on site.
5. NDT Testing, Load Test, and Certification
A lifting tool must not be operated before passing a series of extreme physical tests. The most crucial stage is the execution of Non-Destructive Testing (NDT) on all welding areas. We carried out Penetrant Testing to detect fine cracks on the metal surface.
Furthermore, we also performed Ultrasonic Testing (UT Test) on all auxiliary tools. This ultrasonic testing is done twice: before and after the Load Test. The Load Test itself is an extreme load test exceeding the tool’s safe working capacity.
Once all lifting tools and mounts passed the Load Test without deformation, the tools were certified. The final finishing stage involved wire-brushing and painting. The official Handover Certificate (BAST) report for this project was signed in early July 2023.
Conclusion on the Reliability of PT ASC Lifting Tools Fabrication
The completion of this special tools project for the overhaul area in Cilegon is an exceptional achievement. This lifting tools fabrication process was completed thanks to in-depth and meticulous engineering calculations. The synergy between mechanical expertise, load test quality control, and punctuality operated optimally.
The turbine facility at PT Asahimas Chemical now possesses maintenance equipment that is 100% proven safe. The reliable readiness of all these special tools is fully guaranteed through a consecutive six-month quality warranty.
Does your industrial company require officially certified special lifting equipment fabrication modifications? Please contact our internal expert representatives immediately to discuss technical specifications. We are always ready to realize the most robust mechanical construction equipment for your plant’s operational safety.
