[Pegasus Lifting] Helps the smooth progress of the Indonesian hydropower project!

Recently, the cooperation project between Henan Pegasus Crane and Batubrak Mini Hydroplant Project (Indonesia's Batubulak Small Hydropower Station Project) was successfully delivered. This cooperation is a milestone in the development history of Pegasus Crane. The deep recognition of international friends' government projects is a testimony of Pegasus Crane's extremely competitive strength and an inexhaustible driving force to spur Pegasus's rapid development.

Project background:

Indonesia has been facing a serious power shortage for a long time. Batubrak Mini Hydroplant Project Project is located in Lampung Province (the southern tip of Sumatra Island, Indonesia, facing the sea on three sides). It is a key project of Indonesia's National Electric Power Company's 2016-2025 power supply plan. It aims to alleviate the power supply shortage in Lampung Province, adjust Indonesia's national energy structure, and promote local employment and economic development through the construction of PLN Lampung Power Station, crane is an essential hoisting equipment, especially in the dam concrete construction of hydropower projects, the dam height is high, the concrete earthwork is the largest, the concrete transportation and pouring equipment capacity is large, the efficiency is high, to meet the requirements of continuous operation of large warehouse surface, the driving equipment requirements are higher, the driving equipment manufacturers are also a severe test.

 

 

Project significance:

The construction of Batubrak Mini Hydroplant Project project is conducive to alleviating the long-term power supply situation in Indonesia, and is of great strategic significance to promote and accelerate the development of Indonesia's domestic economy. Indonesia's national power supply plan provides an important opportunity for Chinese lifting enterprises to "go global", and also provides important equipment support for Pegasus Crane to participate in international projects on behalf of Chinese lifting enterprises, and to bring new technologies, new equipment and better energy structure adjustment to coastal countries.

In order to fully assist the strategic advancement of the Indonesian hydropower project, Pegasus Crane actively advised customers, analyzed the implementation of the strategy, analyzed the particularity of the driving requirements of the hydropower construction, and jointly discussed solutions.

Project Difficulties:

1, overseas epidemics continue to spread, international cooperation is facing communication difficulties, meeting difficulties, inspection difficulties and other severe tests, how efficient, accurate and unimpeded communication, to determine the equipment program, is the first major difficulty of this cooperation;

2. In order to play a better overall efficiency, driving needs more professional and accurate design and technology, and more needs strong technical strength to support;

3. The environment of the hydropower station project is humid and the operation intensity is large, which is very different from the traditional driving standard requirements. The driving needs better corrosion resistance, waterproof, stable performance, higher efficiency, longer durability, and higher safety factor. The quality and adaptability of the whole machine are the third difficulty;

4. Detailed requirements.

The acceptance report of this project is issued by a third-party testing agency. The inspection is more comprehensive and requires higher requirements, mainly including the following aspects:

1) Sensory testing, including seeing, listening, smelling, asking, touching and other on-site testing;

2) sub-item inspection of testing instruments, in the original state of lifting equipment, the use of testing and diagnostic instruments and expert monitoring system, the lifting machinery for testing;

3) Safety inspection of general parts, including hooks, wire ropes, braking devices, drums, pulleys, reducers, wheels, couplings, etc;

4) Inspection of safety protection devices, including overload protection devices, torque limiters, limit position limiters, windproof devices, anti-overturning devices, buffers, protective devices, etc;

5) Electrical control devices, including control devices, electrical protection devices, etc;

6) Inspection of metal structure details, mainly to see whether the stressed components are stable, whether there are fatigue deformation, cracks, corrosion and other phenomena;

7) In the driver's cab, check the firmness of the suspension and support connection of the cab, and check whether the door lock and door electrical interlocking switch, insulated floor and dry powder fire extinguishing configuration of the cab are complete and effective;

8) Safety signs, check whether the crane weight signs and qualified signs are sprayed.

Solution:

Pegasus Lifting has never been afraid of difficulties. It is the spiritual inheritance of Pegasus for 30 years to forge ahead. Pegasus Lifting knows that this cooperation is of great significance. In the end, the quality, performance and matching degree of the whole crane are the key to determine whether this crane can be delivered smoothly. Pegasus Lifting believes that good lifting equipment must be an amazing combination of precise calculation and reasonable design of precision craftsmanship.

For this reason, Pegasus has paid special attention to equipment requirements from the beginning. Due to time difference, it often communicates with Indonesian customers until late at night, which lays an important foundation for the later technical team to carefully consider every detail and accurately calculate every parameter. From the selection of raw materials, product design, selection of accessories to the installation of the whole machine, Pegasus crane carefully treats every link, accurately controls, strengthens process and project management, strictly controls quality inspection and testing, and ensures the excellent quality and stable performance of the whole machine.

Compared with traditional lifting equipment, this project is much more difficult, which is a new challenge for Pegasus lifting designers. Related accessories include engines, motors, materials, control components, and hydraulic components; in design technology, control technology and hydraulic technology are involved; design theory involves solid mechanics, structural mechanics, statistical mechanics, optimization theory, etc. Whether the project finally meets the standard not only represents the design and manufacturing level of Pegasus lifting, but also reflects the international technical level of China's lifting manufacturing. Therefore, it can only succeed and is not allowed to fail.

Partial structure diagram of crane equipment

The person in charge of Pegasus lifting said frankly: "The export of lifting equipment to foreign countries is not only a problem for Pegasus's own enterprises, but also an important voice for Chinese brands in the international market. We can't simply manufacture the equipment and end it, but we should consider driving in the construction of the entire hydropower project to better connect upstream and downstream operations, involving a series of issues such as performance, efficiency, quality, volume and safety." The hydropower project has many requirements for crane equipment. The early design of the equipment itself is a complex and systematic work. We must communicate with customers, technology and other aspects repeatedly, continuously strengthen technical exploration, accurately analyze the basic characteristics of cranes and master working skills, so as to completely overcome the problems and give full play to the role of crane.

Details of cooperation:

1. Cutting and blanking: Design and calculate according to the requirements of the project on equipment performance parameters, external dimensions, quality, etc., and design the crane operating mechanism and bracket in the form of drawings; All plates have been strictly screened and inspected, and all have been pretreated before blanking.

Cutting and blanking in strict accordance with the design

2. Processing and production: strictly set the welding sequence and reduce the welding deformation through a reasonable welding sequence; After welding, the vibration effect shall be treated to eliminate the welding stress. The detection methods and instruments required by the national standards shall be adopted and tested without sunshine, and the assembly process shall be carried out in accordance with the requirements.

3. Assembly of the whole machine: Before assembly, the staff must be familiar with the component construction drawing and relevant technical requirements, and review the quality of the parts to be assembled according to the construction drawing requirements; All components in the pre-assembly shall be sized according to the construction drawing. The center of gravity line of each member shall meet at the node center and be completely in a free state. No external force is allowed to be forced to fix.

4. Quality inspection and test of the whole machine: After the assembly of the whole machine is completed, strict quality inspection of the whole machine will be carried out, ranging from lifting trolley to weld screws, and the inspection will be carried out one by one. After the quality inspection of the whole machine is passed, the driving simulation test will be carried out. The lifting mechanism and the operating mechanism will perform repeated lifting, operation, parking, forward rotation, reverse rotation and other operations according to the working level. The operation will be accumulated for 8 hours to observe whether each operating mechanism is stable and whether each performance meets the design requirements. After the simulation test has no problems, a qualified report will be issued.

Perform simulation experiments after the equipment is completed

5. Acceptance and Delivery: After all internal inspections and tests are completed and confirmed to be correct, Pegasus Crane invites Indonesian customers to visit the site for acceptance and provides inspection procedure instructions. Pegasus Crane technicians will lead Indonesian customers to inspect item by item. It mainly includes the maintenance of equipment installation accuracy, whether the equipment transmission, operation, control, lubrication, hydraulic, pneumatic and other systems are normal, and whether the equipment vibration, noise, temperature of mechanical parts (such as bearings), leakage of hydraulic and pneumatic system, leakage of lubrication system, operation, transmission, control, automatic function, safety and environmental protection devices are normal, stable and reliable in load test, totaling more than 40 items. The number of acceptance items and the rigor of the process gave Indonesian friends thumbs up and praise.

Equipment sub-item acceptance

In the construction process of the project, how to make the arm frame lighter and the largest lifting weight, in the structural form, Pegasus lifting adopts the topological optimization design method, reasonably solves the problem of strength and stability, and adopts the method of combining precise solution and numerical method to determine a more reasonable arm frame weight. From the basic performance parameters, boom range, to determine the analysis frame section size and reasonable lifting point position, to provide a scientific basis for detailed design. In the case of reasonable and perfect design, the comprehensive design method aiming at the comprehensive quality of equipment is the central direction of this project, and it also meets the comprehensive performance requirements of users for products to the greatest extent.

After the delivery of the project, the strength of Pegasus lifting hard core products has been highly recognized by users.

Equipment Acceptance Report

6. Packaging and delivery: The driving volume is huge and heavy. It can only be sent to Lampung Province in Indonesia by sea. The shipping journey is long and the cycle is long. Pegasus crane intimately disassembled the crane and packed it in a sealed container and rainproof cloth. To prevent the sun and rain on the road, let the car with a new look directly to the Indonesian construction site.