Electric Explosion Proof Winch for Oilfield Flare Towers Installation
Explosion proof electric winch designed for oilfield flare tower installation in Nigeria. Customized electric winch + ATEX explosion proof parts for sale.
Background of the Italian client for explosion proof winch
The explosion proof electric winch is designed for an Italian company , which is specializing in the manufacture of oilfield flare towers. The function of the oil field flare tower is to collect some flammable, explosive and other dangerous gases (mainly methane, ethane, etc.) for burning and consumption in the process of oil and gas exploitation, so as to avoid danger to construction workers.
This time, the Italian customer is providing flare towers for the new oilfield project of A American Oil Company in Nigeria. There is a set of gas guide pipes on the side of the flare tower, which requires an explosion-proof winch for installation and maintenance.
Working conditions and hoisting requirements
Oilfiled flare tower
explosion proof winch for oild firled flare tower installation The gas pipe of the flare tower is assembled from several independent pipes. The weight of a single pipe is 5-8 tons, and the total weight of all pipes is 80-100 tons. All pipes need to be lifted and installed from the ground one by one.
The lifting process of the steel pipes is:
- 1. Firstly, use an electric winch to pull the first section of gas pipeline lying flat from the ground to be perpendicular to the ground, that is, parallel to the flare tower. The lifting point is the top of the gas pipeline, and it is equipped with a movable pulley for easy turning. The hoisting winch selected by some customers is JM10 ton , referred to as flip winch.
- 2. Transfer the pipe pulled up in step 1, transfer the weight to another hoist, and perform vertical pulling operation. The electric winch type is JM25T, referred to as hoisting winch.
- 3. Use the turning winch to pull down the remaining pipelines on the ground again. When the second section of the pipeline is in place, it will be rigidly connected to the first section, and then use the hoisting hoist to perform vertical lifting operations.
- 4. Repeat the above steps until all the pipes are installed in place.
Analysis of explosion proof winch requirements
1. Analysis of the pulley of the flip electric winch
The turning winch (JM10 ton electric winch ) is installed on the ground, and the pulley system consists of steering wheels D1, D2 and the movable pulley M1 at the end of the pipe.
2. Analysis of vertical hoist winch pulley
The vertical lifting winch (JM25T) is installed on the ground. The pulley system consists of steering pulley D1, fixed pulley block D3 and movable pulley block M2, in which D3 and M2 are three-piece pulley blocks with a ratio of 6/1, so the actual pulling force of the JM25T winch is enlarged 1500KN (150 tons) to lift the assembled 100-ton main pipeline.
(In order to simplify the working conditions, the steering wheels marked with red circles in the figure are temporarily ignored)
Steel wire anchors and wedge sleeves
The pull-turn winch JM10T and the vertical lift winch JM25T both have a single-exit rope, but both are equipped with a pulley, so the end of the wire rope needs to be fixed at an anchor point, as shown in the basket ring on the right.
A set of wedge sleeves is required for fixing the anchor point and the wire rope, which are also provided by us. The shaft of the wedge sleeve can be reversed to cope with the rotation when the wire rope is pulled, thereby reducing the torsion, improving the life of the wire rope, and increasing construction safety. The wedge sleeve is imported from the United States, and the shaft and the wire rope are treated with glue, as shown in the figure below.
Both explosion proof winch have:
1.ATEX BT3
The explosion-proof parts of the electric winches are mainly the motor, brake and electrical box. The explosion-proof level of the electric winch in the European Union is ATEX. The explosion proof winch is designed with Siemens motors, Siborui brakes and Nanyang Zhongtong electric appliances, all of which have ATEX certificates.
2. The wire ropes of the two electric winches meet the safety factor of 5, that is, the minimum breaking force is more than 5 times the rated pulling force. The original steel wire rope has a factor of 3~4 times. Solution: replace it with Langshan steel wire rope, and increase the tensile strength to 1960 N/mm² (JM10T) and 2160 (JM25T) N/mm².
3. Exporting to Nigeria requires PC&SONCAP certificates, and the third party inspection is provided base on client requirement.
4. NDT non-destructive testing requires raw material UT (ultrasonic testing), weld MT (magnetic particle testing) testing.
