EN 
ES Project Overview
In hazardous industries such as oil refining and petrochemical processing, lifting equipment must do far more than simply move loads. Extreme temperatures, explosive atmospheres, confined operating spaces, and demanding maintenance schedules often require highly customized solutions rather than standard crane configurations.
Recently, Yuantai Crane engineered and delivered a custom 200kg explosion-proof pillar jib crane for a modern oil refinery in Saudi Arabia. Designed for installation on a high-elevation process platform, the system combines long-distance vertical lifting, dual-certified explosion protection, and outdoor-duty durability to support safe and efficient refinery maintenance operations.
Project Specifications
| Item | Specification |
| Equipment Type | Outdoor Explosion-Proof Jib Crane |
| Safe Working Load | 200 kg |
| Slew Radius | 2.15 m |
| Total Lifting Height | 63 m (2.55m+60.45m) |
| Pillar Height | 3.25 m |
| Rotation Angle | 300° Motorized Slewing |
| Slewing Speed | 1 m/min |
| Hoist Type | Explosion-Proof electric chain hoist |
| Hoist Lifting Speed | 2.7 / 8.2 m/min |
| Hoist Travel Speed | 3–11 m/min |
| Power Supply | 480V / 60Hz / 3Phase |
| Control Method | Wireless Remote + Pendant Control |
| Duty Class | ISO A5 |
| Explosion Protection | Ex db IIC T4 Gb / Ex tb IIIC T130°C Db |
| Protection Grade | IP65 |
| Insulation Class | F |
The Challenge: High-Elevation Hazards
The refinery required a dedicated lifting solution for a reactor platform 60.45 meters above ground. Unlike workshop applications, this project presented four simultaneous engineering hurdles:
- Extreme Vertical Distance (63m total): Lifting speed, positioning accuracy, and load stability become critical at this elevation.
- Hazardous Atmospheres: Flammable gases and combustible dust require dual-certified explosion protection (gas + dust) to eliminate ignition risks.
- Confined Platform Space: Dense piping and limited visibility to ground level demanded precise load positioning and flexible operator control.
- Harsh Desert Climate: Ambient temperatures exceeding 50°C, intense UV, and frequent sand intrusion required IP65 sealing and heavy-duty corrosion resistance.
Engineering Solution
To address these challenges, the outdoor jib crane system was specifically configured around the refinery’s operating conditions rather than adapted from a standard design.
Dual-Speed Lifting for Long Vertical Travel
One of the most important design considerations was the 63-meter lifting height.
A single-speed hoist would either slow maintenance operations or make precise positioning difficult when approaching the platform.
To balance efficiency and control, the crane was equipped with a dual-speed explosion-proof electric chain hoist:
- 8.2 m/min high speed for rapid travel through the majority of the lifting distance
- 2.7 m/min low speed for precise positioning near loading and unloading points
This arrangement significantly reduces maintenance waiting time while maintaining accurate load handling where precision matters most. The compact chain hoist design also minimises structural loading on the jib arm compared with alternative lifting configurations.
Flexible Dual-Control Operation
Because operators may be located at different elevations during maintenance work, the control system was designed to provide maximum operational flexibility.
The pillar-mounted jib crane incorporates:
- Explosion-proof wireless remote control for unrestricted operation from optimal viewing positions
IP65-rated pendant control as a hardwired backup system - This dual-control arrangement helps eliminate communication blind spots while ensuring uninterrupted operation during maintenance activities.
Dual-Certified Explosion Protection
Drawing on extensive experience in hazardous-area lifting applications, the system was engineered to protect against both gas and dust ignition risks.
Certification includes:
- Ex db IIC T4 Gb for explosive gas atmospheres
- Ex tb IIIC T130°C Db for combustible dust environments
The design complies with internationally recognized hazardous-area requirements commonly applied throughout the oil and gas industry.
Outdoor Protection Package
To ensure long-term reliability in Saudi Arabia’s desert climate, the crane incorporates several protective measures:
- IP65-sealed electrical enclosures
- Heavy-duty anti-corrosion coating system
- Dust-resistant motors and gear assemblies
- Class F insulated motors for elevated ambient temperatures
- Weather-resistant components suitable for year-round outdoor service
The motorized slewing mechanism also operates at a controlled speed of 1 m/min, helping reduce load swing during rotation in exposed high-elevation conditions.
Heavy-Duty Structural Design
To ensure long-term reliability under these demanding conditions, the jib crane was engineered to ISO A5 duty classification. This heavy-duty design standard provides:
- Higher resistance to structural fatigue under repeated load cycles
- Increased reliability during intensive maintenance operations
- Extended service life for key mechanical and electrical components
- Reduced maintenance requirements and lifecycle costs
Whether lifting maintenance tools, replacement valves, instrumentation components, or catalyst materials, the electric jib crane is designed to deliver consistent performance throughout demanding refinery maintenance schedules.
Project Value & Current Status
This custom solution effectively neutralised the risks of extreme height, explosive dust/gas, and severe climate in one integrated design. The 200kg explosion-proof jib crane has completed factory testing and is currently en route to the Saudi site. Upon delivery, Yuantai Crane will provide remote installation guidance and commissioning support to ensure a seamless operational handover.
Looking for a Custom Explosion-Proof Lifting Solution?
From customized explosion-proof jib cranes and electric hoists to overhead cranes and gantry crane systems, Yuantai Crane provides tailored lifting solutions designed around each customer’s specific operational requirements.
Whether your application involves refinery maintenance platforms, chemical processing facilities, offshore projects, or other hazardous-area installations, our engineering team can assist with equipment selection, design, manufacturing, remote installation support, and commissioning guidance.
Contact Yuantai Crane today to discuss your project requirements and receive a suitable lifting solution proposal.
