Structural Challenge: 737 tons in a single maneuver in India

At AITESA, we took on the challenge of designing and calculating the support structure for an air preheater in one of the largest energy and petrochemical companies in India. Beyond supporting the load of the equipment in operation, the design had to ensure that the structure also functioned as a lifting frame, allowing its assembly in a single crane maneuver with a total weight of 737 tons.

• Width: 10.70 m
• Edge: 2.90 m
• Height: 14.64 m
• Total installed weight: 630 tons

However, the real challenge was not only to design a structure capable of supporting the load of the equipment and its pipelines in operation, but also to ensure that it could serve as a lifting frame for assembly in a single crane maneuver. This involved a total lifting weight of 737 tons, which required careful structural analysis and optimized design for the operation.

• Supporting structure: Designed according to IS800 code for the operation of the installation and reinforced to ensure safe lifting without compromising the integrity of the equipment.
• Lifting frame: Configured with heavy-edged beams and reinforced lugs to optimize load distribution and ensure a safe vertical pull.
• Lifting lugs: Analyzed using finite element software to evaluate their strength, including strategically designed reinforcements and welds.

This project is a clear example of how structural engineering and innovation can successfully address the challenges of large industrial complexes worldwide.