In refinery, petrochemical and gas plants, the heat-exchanger cycle—pull → clean/inspect/retube → re-insert—often dictates turnaround duration. Relying on cranes and heavy manual handling means large footprints, long waiting times, and higher safety exposure. Our Tube Bundle Extractor is engineered for rapid pulling and precise re-insertion at the unit, helping owners and service contractors compress schedules and reduce downtime.
Why a Tube Bundle Extractor?
1) Speed & predictability
Integrated guiding and pulling system delivers stable, repeatable cycle times.
Works in sequence with hydro-jetting, NDT (ET/UT/RT), and retubing—no crane queuing.
2) Small footprint, simple organization
Designed for tight pipe racks and congested units; no long crane occupation.
Mobile base and quick alignment enable multi-exchanger serial/parallel work.
3) Safety & control
Proportional hydraulics with force monitoring; automatic alarm/stop on abnormal load.
Remote operation keeps people at a safe distance; structure verified for strength/fatigue.
Platform & Coverage
Drive options: Electric (EMP) / Diesel (D)
Rated pulling force: 20–115 tons (higher capacities on request)
Bundle size envelope: Ø up to 3,000 mm; length 6–12 m (front/rear extensions up to 15 m)
Typical units: Crude/Vacuum, Aromatics, Olefins, Fertilizer, HRSG/WHRU, LNG and gas processing
Electric version (EMP): zero on-site emissions, low noise, fast start/stop—ideal for indoor and emission-restricted areas.
Diesel version (D): highly mobile with minimal power dependency—suited to remote and outdoor sites.
Design Highlights
A. Guidance & clamping
H-beam frame with adjustable rails ensures straight-line pulling; six-point alignment reduces shell damage.
Quick-change lifting points/clamps for different flange spaces and mounting orientations.
B. Proportional hydraulics & force monitoring
Fine jogging and micro-movement for effortless re-insertion and flange bolt-up.
Real-time force/position monitoring with auto alarm/stop protects both machine and bundle.
C. Winch system
Large-diameter drum and hardened sheaves extend rope life; safety factor ≥5.
Optional twin synchronized winches for long or off-balance bundles.
D. Controls & remote
Dual wired/wireless remote; operator stands at the best view and safest distance.
Interlocks on clamp/lock, travel and pull/reverse to prevent mis-operation.
E. Serviceability
Front-access lubrication and wear parts; standardized spares for fast replacement.
Remote diagnostics plus on-site technical support.
Compared with Crane-Based Methods
Aspect Crane + Manual Tube Bundle Extractor
Organization Crane scheduling, road closures Set, align, pull—straightforward
Footprint Large, long occupation Compact, pipe-rack friendly
Cycle stability Queueing & re-alignment Proportional micro-control
Safety Close contact & working at height Remote, separation of people & load
Cost High crane day-rates & waiting Purchase/rental amortized across TAs
Example: for an Ø1600 × 12 m exchanger, one pull + re-insert cycle can be 20–40% faster than a crane-led method. With 8–12 exchangers per unit, turnaround windows shorten noticeably.
Typical Workflow
Position & align: survey → spotting → six-point alignment → clamp/lift points
Pull: proportional draw with force/position monitoring → controlled stop
Service: hydro-jetting, NDT, retubing/expanding
Re-insert: micro-movement → flange bolt-up → torque verification
Handover: quick checks, photos/video, and a short report
Delivery & Services
Right-sizing: model mapping to your common bundle diameters/lengths/weights with cycle-time estimate
Demo & training: in-house demo or on-site trial; operator training with safety checklist
Rental & manning: short-term rental and operator dispatch for critical TA windows
Spares & support: stocked wear parts, remote diagnostics, and field service
FAQs
Q1: Tight flange space or limited clearance—usable?
Yes. Narrow clamps and low-profile guides are available. Front extensions and inverted mounting options address tight geometries.
Q2: How to ensure quick bolt-up without damaging gaskets?
Proportional jog/micro-move plus six-point alignment and jack-bases give clean, fast hole matching and reduced gasket wear.
Q3: Do we need diesel?
Not necessarily. The Electric (EMP) version is zero-emission and low-noise—ideal for indoor/regulated areas.
Q4: Can we rent first?
Absolutely—short-term rental and “rent-to-buy” programs are available, with operators if required.
Let’s Plan Your Next TA
If you’re scheduling exchanger maintenance, we’ll map the right model and propose an hour-by-hour cycle for your site.
Email: wuxian@qingweiequipment.com
WhatsApp / Phone: +86-186 2443 3099
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In one line: a reliable Tube Bundle Extractor makes your turnaround faster, steadier and safer.
