The client is a large-scale core petrochemical refinery located in the Al Jubail Industrial Zone, Saudi Arabia. The facility is mainly engaged in crude oil refining, chemical pipeline operation, and periodic high-altitude maintenance of reaction equipment. The site belongs to typical coastal high-temperature and high-salt-fog environment, and is classified as a Zone II explosive hazardous area, which puts forward extremely strict requirements for equipment explosion-proof performance, anti-corrosion capability and operational safety. Traditional temporary scaffolding and ordinary lifting equipment cannot meet long-term stable overhaul demands. We designed and customized a 3-ton heavy-duty triple scissor maintenance platform with integrated access stairs for this client; the project including explosion-proof optimization, full anti-corrosion treatment, structural customization and on-site commissioning has been successfully completed, and the equipment is fully operational for daily refinery maintenance work.

Zorluk ve Çözüm

Müşteri Zorlukları

The petrochemical refinery’s high-altitude maintenance workflow faced multiple severe engineering bottlenecks affected by coastal harsh climate, hazardous explosion environment and limited overhaul space.

Explosive Hazardous Environment Safety Risks: The refinery operation area belongs to Class II flammable gas hazardous zone. Standard industrial lifting equipment generates electric sparks during startup and operation, which poses major explosion and fire hazards, failing to meet petrochemical intrinsic safety standards.

Severe Coastal Salt-Fog Corrosion Aging: Located on the Saudi Arabian coast, the site is eroded by high-chloride sea breeze all year round. Ordinary steel structures are prone to rust, scissor shaft jamming and hydraulic component aging, resulting in frequent equipment failure and shortened service life.

High Load & Ultra-High Lifting Stroke Limitation: Pipeline and reactor maintenance requires simultaneous carrying of multi-person maintenance teams, heavy tools and spare parts with a total load of 3 tons. Conventional single and double scissor structures cannot achieve high lifting height within restricted on-site installation footprint.

Temporary Scaffolding Low Efficiency & Hidden Dangers: Traditional temporary scaffolding requires repeated assembly and disassembly, consuming massive manpower and long preparation time. Without fixed access passages, staff climbing and tool transfer are unstable, leading to high falling risk and low maintenance efficiency.

Local Industrial Standard Compliance Constraints: All on-site operating equipment must comply with Saudi SASO industrial standards and EU mechanical safety specifications, requiring standardized explosion-proof configuration, anti-corrosion process and safety interlock system certification.

GRADIN Özel Çözüm

To solve the high-altitude maintenance difficulties of the corrosive and explosive petrochemical working conditions in Al Jubail, our engineering team developed a customized heavy-duty triple scissor lifting platform: TS-3000-JUB. This machine integrates triple superposition scissor kinematic structure, explosion-proof hydraulic system, full anti-corrosion treatment and integrated access stairs, realizing safe, stable and efficient intelligent maintenance operation.

1. Dual-Action Kinematic Architecture

The whole machine adopts Q355B high-strength low-alloy steel integral cutting and welding structure, equipped with triple superimposed scissor linkage mechanism. The multi-stage scissor design achieves ultra-high lifting stroke with small ground occupation, perfectly adapting to the refinery’s compact overhaul space. All load-bearing beams adopt thickened seamless rectangular steel tubes, and all rotating pivot points are equipped with SKF anti-corrosion self-lubricating bearings to prevent shaft jamming caused by salt fog and dust accumulation, ensuring long-term flexible mechanical movement.

2. Synchronized Hydraulic and Torque Management

The equipment is equipped with REXROTH professional explosion-proof hydraulic power unit and customized heavy-load hydraulic cylinders. Adopting pressure balance and flow stabilization hydraulic circuit design, it maintains constant lifting speed under 3-ton full-load operation and avoids platform shaking and tilting during high-altitude lifting. Equipped with pipeline rupture safety valve and overload overflow protection device, it effectively prevents platform free fall and structural impact damage caused by sudden oil circuit failure, ensuring stable torque output and high-altitude load balance.

3. Integrated Access Stair Structure Design

Different from ordinary split lifting platforms, this solution adopts factory-integrated one-piece access stairs. The stair frame is welded with high-strength steel and paved with anti-slip patterned steel plates, equipped with full-height safety handrails and anti-fall guardrails. The stair and the main platform share the same anti-corrosion process, realizing stable and safe walking passage from ground to high-altitude platform. It completely cancels temporary scaffolding erection, realizing one-stop docking for personnel boarding and tool transportation.

4. Electrical and Safety Integration

The whole electrical system is customized for petrochemical Zone II explosion-proof environment, fully complying with local Saudi industrial power standards. All electrical components adopt Ex d II BT4 explosion-proof grade, including SIEMENS explosion-proof PLC core control system and Schneider low-voltage explosion-proof distribution components. The system adopts SICK explosion-proof photoelectric limit switches for precise height interlock control. Equipped with full-stroke mechanical anti-fall protection, overload alarm system and emergency stop device, it realizes multi-dimensional safety redundancy for hazardous working conditions.

Teknik Parametreler & Destekleyici Markalar

Teknik Parametreler

Parametre	Şartname
Nominal Yük Kapasitesi	3.000 kg (3 Metrik Ton)
Platform Boyutları	8,000 mm × 2,500 mm
Maximum Platform Height	6,000 mm
Closed Height	1,550 mm
Structural Material	High-Strength Structural Steel
Kaldırma Mekanizması	Triple Scissor Hydraulic Structure
Explosion-Proof Classification	ATEX Zone 2 / IECEx Hazardous Area Standard
Güç Kaynağı	480V / 60Hz / 3-Phase
Motor Configuration	Explosion-Proof Industrial Motor
Environmental Protection Grade	IP66 Electrical Protection / C5-M High-Grade Anti-Corrosion Coating System
Access System	Integrated Fixed Access Staircase
Safety Compliance	ANSI/SAIA A92.20 / SAES Industrial Standard Requirements
Designed Service Life	15 Years

Destekleyen Markalar

Our customized petrochemical-grade scissor lifting platform adopts premium international brand components for explosion-proof electric control, hydraulic power, mechanical transmission and safety induction parts to ensure intrinsic safety and long-term stable operation in hazardous corrosive environments.

1. Elektrik Kontrol Bileşenleri

High explosion-proof grade parts ensure stable and safe program operation in flammable and explosive environments

•SIEMENS: Explosion-proof PLC, core control modules and low-voltage control units

•Schneider: Explosion-proof contactors, relays and safety switch components

2. Pnömatik ve Hidrolik Bileşenler

High-stability hydraulic accessories guarantee constant load-bearing and smooth lifting performance

•REXROTH: Explosion-proof hydraulic pump station, pressure stabilizing valves and pipeline protection valves

3. Mekanik Transmisyon Parçaları

Anti-corrosion and wear-resistant mechanical parts adapt to long-term coastal harsh working conditions

•SKF: Anti-corrosion self-lubricating bearings and high-precision rotating assemblies

4. Safety Induction & Protection Parts

High-sensitivity safety components realize precise limit and anti-collision protection

•SICK: Explosion-proof photoelectric sensors and high-precision limit detection devices

Proje Yürütme ve Başarılar

Uygulama Detayları

Uygulama ve Başarılar

For the petrochemical refinery in Al Jubail, Saudi Arabia, we provided a customized 3-Ton Triple Scissor Maintenance Platform with Integrated Access Stairs. This explosion-proof and anti-corrosion all-in-one maintenance solution replaces traditional inefficient and unsafe temporary scaffolding operations. It effectively solves the problems of poor high-altitude operation safety, low maintenance efficiency, severe equipment corrosion and non-compliant safety configuration in petrochemical hazardous areas.

1. All-In-One Integrated Process Optimization

Traditional refinery high-altitude maintenance relies on temporary scaffolding and simple lifting tools, requiring repeated assembly, disassembly and position correction before each overhaul. This integrated triple scissor platform with built-in access stairs realizes one-stop personnel boarding, heavy-load material transportation and fixed high-altitude operation. It eliminates intermediate auxiliary operation links, standardizes the maintenance workflow, and greatly improves the continuity of refinery equipment overhaul.

2. Greatly Improved Production Efficiency

The original scaffolding assembly and dismantling process consumes a large amount of preparation time, resulting in long overhaul cycles and low equipment turnover efficiency. The fixed integrated lifting platform can be put into use at any time, realizing rapid response to equipment maintenance demands. It improves comprehensive high-altitude maintenance efficiency by over 80%, greatly shortens the shutdown overhaul cycle of petrochemical equipment, and increases the factory’s effective operating time.

3. Stable Processing Accuracy & Zero Operation Safety Hazards

Temporary scaffolding has poor structural stability and is prone to shaking and deformation, easily causing personnel falling and tool dropping accidents. The heavy-duty triple scissor rigid steel structure and balanced hydraulic system ensure zero shaking and stable high-altitude positioning under full load. The full explosion-proof configuration eliminates electric spark risks in hazardous gas environments, realizing zero safety accidents and zero operational hazards during long-term maintenance work.

4. Remarkable Labor Cost Reduction

The traditional maintenance mode requires multiple workers to complete scaffolding erection, equipment transfer and high-altitude auxiliary operations. This automated fixed lifting platform supports single-person control for the whole process. It greatly reduces labor input for pre-maintenance preparation, eliminates efficiency differences caused by manual operation, and maintains stable and efficient maintenance output all year round.

5. Customized Adaptation for Harsh Petrochemical Coastal Conditions

Tailored for Saudi coastal high temperature, high salt-fog corrosion and petrochemical explosive hazardous environment, the whole machine adopts Q355B high-strength steel and professional multi-layer anti-corrosion coating technology. The full explosion-proof electrical configuration fully meets Zone II hazardous area standards and Saudi local industrial certification requirements. The integrated stair structure perfectly adapts to long-term continuous high-intensity maintenance operations of refinery projects.

Genel Proje Faydaları

After equipment commissioning and formal operation, the client’s refinery overhaul efficiency improved by more than 80%, with zero safety accidents and zero equipment failure caused by environmental corrosion. The standardized integrated lifting platform realizes safe, automated and standardized high-altitude maintenance operations, effectively optimizing the factory’s equipment management system and significantly improving the overall operational safety and market competitiveness of the petrochemical plant.

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