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Self Propelled Bundle Extractor
Industrial Professional Tube Bundle Puller
Professional tube bundle extractor and bundle puller system enables heat exchanger maintenance. The equipment operates in refineries and petrochemical plants and power stations worldwide.
25-Ton Bundle Capacity
50-Ton Pulling Force
Remote Control Operation
8000mm Max Length
VIEW: ORTHO-01
Bundle Alert Awareness
What Is a Self-Propelled Bundle Extractor?
A self-propelled bundle extractor is designed as a specialized maintenance asset that is bound to function towards the same operation of handling tube bundles in heat exchangers. In contrast to the traditional setups of crane-operated, or truck-mounted bundle extractor systems, our self-propelled unit integrates hydraulic power, precise control, and individual mobility into one small unit.
01
Individual Mobility
It has got autonomy, so technical gadgets operate it. Suitable for managing the crane suddenly taken away from it, thereby saving set-up time and labor input.
02
Hydraulic Precision
The advanced hydraulic system realizes smoothing and performance with the help of the controller.
03
Wireless Control
Radio-controlled fob operation keeps the worker 100% safe during its system of pulling.
Time is the Essence.
✓ The setup time is 60% less compared to crane methods
✓ The perennially improving safety
✓ Has the ability to be remotely operated and is given constant stability
✓ Brings in cost effectiveness
✓ Cost considerations like the operating costs of the mechanical system
✓ Is easy to service
✓ Can be subject to ready availability of parts and supportive services
How It Works
Self-Propelled Bundle Extractor Operation & Technical Data
By using our self-propelled bundle extractor, the complete removal procedure has been efficiently simplified to a matter of minutes from being multi-hourly.
1
Position & Approach
Push the self-driven unit right up to the heat exchanger. Its compact design allows maximum maneuverability through tight refinery corridors where other truck-mounted systems cannot access.
2
Height Adjustment
One would now simply go beyond that and drive the manipulator base into the heat exchanger with clear line of sight. An operator will control his own drive function onto the tube bundle by standing and craning his neck inside the tube bundle far off end for all time.
3
Grip & Extract
The hydraulic bundle extractor compresses on the tube bundle and delivers up to a maximum 50 tons of pulling force. Apply guide rails for; tends to be more linear, very well control but only narrow and limited distance of the extraction.
4
Transport & Install
Bring the hauled bundle to maintenance zone. Do the opposite to insertion for the new clear-inserted bundle. Complete very quickly even as high as 8 full turnarounds.
25T
Bundle Weight
50T
Tensile Force
6,000mm
Working Height
8,000mm
Bundle Length
Full Specifications
Factory Data
Model
Self-Propelled Bundle Puller
Max Bundle Weight
25,000 kg
Max Bundle Diameter
2,000 mm
Max Bundle Length
8,000 mm
Max Working Height
6,000 mm
Min Working Height
800 mm
Max Tensile Force
50,000 kg
Driving Speed
10 km/h
Control System
Wireless Remote
Power System
Hydraulic + Diesel
Key Features
Bundle Puller Machine Manufacturer Advantages
Every step mentioned here has been taken to ensure that the tube bundle handling in heavy industrial ambiance with emphasis on efficient operations, safety, and cost-effectiveness.
01
Wireless Remote Control
Full operation control from a safe distance. Manage lifting, height adjustment, push-pull force, and steering from outside the operators exposed to harm.
02
Advanced Hydraulic System
Hydraulic circuits precisely matched for torque offer consistent 50-ton pull force, slow but forceful, preventing harmful abrupt tube-sheet impact.
03
Self-Propelling Mobile
An independent drive aims at manoeuvring 10 km above floor level, perfectly capable of functioning on its own under separate steering and transmission.
04
Adjustable Working Height
For placing in desired positions, working height could be adjusted between 800 and 6000 mm and even more for precise hole-nest manipulation.
05
Heavy-Duty Capacity
Supporting a bundle weight of up to 25 tons, made to handle the largest heat exchanger bundles required in refinery/petrochemical applications.
06
Guided Rail Design
Direct extraction path must minimize bundle malalignment or the exposure of bundles to tube damage risk through the push and pull cycle.
07
Stable Wheel Base
An optimized wheelbase with prompt steering controls provides steadiness on rugged materials as well as under heavy loading conditions.
08
Easy Maintenance Access
Convenience handling ease is attained by easy access to all components for routine servicing, facilitating hydraulic checks and filter cleaning.
Our Products
Hydraulic Bundle Extractor Product Range from Japan Manufacture
Complete Range of tube bundle puller equipment for all heat exchanger maintenance applications. Self-propelled, aerial, and truck-mounted models are available.
Best Seller
Self-Propelled Bundle Extractor
Mobile bundle extractor with independently driven system. The most versatile option for plant-wide turnaround operations.
Carrying Capacity
25T – 100T- Working height: 0.8m – 7m
- Wireless Remote Control
- 4-Wheel Steering
Aerial Bundle Extractor
A stationary tube bundle extractor for a workshop and fixed-location operations. Lower cost, simple operation.
Carrying Capacity
15T – 100T- Fixed/Adjustable Height
- Remote Control Standard
- Lower Capital Cost
Truck-Mounted Bundle Extractor
Highway-transportable bundle extractor for service companies and multisite operations. Combine road mobility.
Carrying Capacity
25T – 65T- Highway Speed Transport
- Self-Contained Unit
- Multi-Site Operations
Problems Solved by Us
Bundle Puller vs Crane: Common Extraction Challenges Solved
Challenges in tube bundle extraction are in abundance. The self-propelled bundle extractor we have addresses critical pain points for maintenance teams involved with heat exchanger revamps.
Extensive Loss of Time
The Challenge
Conventionals performing such extractions with the help of cranes end up incurring costs exceeding $100,000 per day as a result of production loss, and set-up times run into hours.
Damage control comes with operational setups in a few minutes. Reduction in extraction times is achieved by the implement of a hydraulic pulling system—just faster than you could ever imagine.
A Daring Gamut
The Challenge
Manual handling exposes persons to danger due to disastrous injuries from handling heavy tubular bundles. Leg and arm injuries are not rare occasions. Dare to crane.
The wireless radio-remote control will enable operators to maintain distance. Together with its design of large stable bin, no moving at all times. Emergency controlled stops are standard on all these systems.
Limitation of Space
The Challenge
Truck-towed machines cannot get to extract bundles located closely inside refinery spaces constraint by the presence of pipe racks.
These are our offerings, among others: self-propelled, compact, narrow-aisle machine. Possessing a low-profile mast and allowing for movement under overhead obstructions. Have you consulted Price Industri? That can be a real benefit.
Damage to Equipment
The Challenge
Inefficient removal methods can cause damage to costly tube bundles and tube sheets and yield a repair cost with a long downtime.
Specially designed hydraulic controls for precision movement. Rails-guided system to keep it aligned properly. Therefore, you can safeguard the valuable equipment components.
Comparison
Self-Propelled vs. Aerial Bundle Extractors: Comparing Extraction Methods
Our bundle extractor delivers better performance than conventional bundle extraction methods which use cranes and truck-mounted systems. The system operates with enhanced efficiency and better safety features together with lower operating expenses which make it the optimal solution for bundle extraction operations..
Feature |
Self Propelled
|
Aerial Bundle
|
Truck Mounted
|
Crane +
|
|---|---|---|---|---|
Independent Operation |
Yes | Yes | Yes | No |
Tight Space Access |
Excellent | Good | Limited | Poor |
Setup Time |
10-15 min | 15-20 min | 20-30 min | 1-2 hours |
Precision Alignment |
Yes | Yes | Yes | No |
Bundle Protection |
High | High | Medium | Risk |
Crew Required |
1-2 persons | 1-2 persons | 2-3 persons | 4-6 persons |
Total Cost of Ownership |
Lowest | Medium | Medium | Highest |
Supported / Advantage
Not Supported / Limitation
Japan Manufacturer
Why Source Your Bundle Extractor From Us
Japan-based bundle extractor manufacturing company provides affordable factory prices together with certified engineers and international quality standards.
Direct Factory Pricing
Eliminate middlemen costs. Our manufacturing facility provides customers with direct access to our pricing system which enables them to receive competitive quotes.
Custom Engineering
We develop bundle extractor solutions which match your exact needs. The company provides custom bundle weight and height range and power configuration options.
International Certifications
The equipment obtained CE certification which confirms its compliance with European safety requirements. The system meets ISO 9001 quality management standards. The system provides ATEX solutions for use in dangerous work areas.
Technical Support
An English-speaking engineering team provides pre-sales consultation and after-sales support for customers. The system provides remote diagnostics together with maintenance guidance.
Fast Delivery
The company uses inventory management and production scheduling to create efficient operations. The company needs between 60 to 90 days to deliver standard configurations which represent its typical delivery schedule.
Quality Assurance
Every bundle extractor undergoes rigorous testing before delivery. Our quality control process ensures each unit meets strict performance and safety standards.
15+
Years Experience
500+
Units Delivered
40+
Countries Served
24/7
Technical Support
Bundle Extractor Capacity & ROI Calculator
Calculate the required pulling capacity and estimate your return on investment with our Self-Propelled Bundle Extractor solutions
Capacity Calculator
kg
mm
mm
Calculation Results
Base Pulling Force Required
—
With Safety Factor
—
Recommended Model
—
ROI Calculator
USD
hours
hours
ROI Analysis
Time Saved Per Turnaround
—
Cost Savings Per Turnaround
—
Annual Cost Savings
—
Efficiency Improvement
—
Ready to optimize your maintenance operations?
Request Custom Quote
Disclaimer: These calculations are estimates for reference purposes only. Actual pulling force requirements depend on specific site conditions, bundle configuration, and fouling severity. Contact our engineering team for precise specifications tailored to your application.
Industrial Applications
Self Propelled Bundle Extractor Applications by Industry
Our tube bundle extraction equipment plays an essential role in supporting critical maintenance of heat exchangers across various industrial sectors worldwide.
Petroleum Refinery
Such applications as maintenance during the turn around of CDUs, Reboilers, Condensers, and Process Heat Exchangers.
Petrochemical Plants
Integrated maintenance solutions for reactors, polymer heat exchangers, and other chemical processing equipment.
Power Generation
Condenser tube bundle pullers for maintenance in thermal and nuclear power plants.
Offshore Platform
Compact design ideal for space-limited offshore installations and FPSO.
Success Stories
Self-Propelled Bundle Extractor Case Studies
These are case studies which highlight the measurable results which self propelled bundle extractors and hydraulic tube bundle pullers have achieved at various locations including refineries and petrochemical facilities globally, and offshore platforms.
Global Petro Refinery: Major Gulf Coast Refinery Reduces Heat Exchanger Turnaround Time by 65% with Self Propelled Bundle Extractor
65%
Time Saved
$4.8M
Savings
0
Incidents
Project Context
As a result of the scheduled turnaround involving the 47 shells and tube heat exchangers maintenance across the crude and fluid catalytic cracking units at the 350,000 barrel-per-day refinery on the Gulf Coast. Each day of downtime turned out to be approximately $1.2 million in lost production. The heat exchangers ranged from 8 to 48 inches and tube bundles ranged from 2,000 to 85,000 lbs.
Challenges
Overhead obstructionsPipe racks limited crane operation, prolonging setup time
Sequential bottleneckOnly two mobile cranes, maintenance one at a time
Safety concernsSuspended loads required large exclusion zones
Variable weights2,000 to 85,000 lbs bundles underutilized crane capacity
Weather delaysGulf Coast conditions disrupted crane operations
Solution: SP-200 Self Propelled Bundle Extractor
Selected
SP-200 Self-Propelled Bundle Extractor
200-ton extraction capacity
Repositioning: 4hrs → 25min
14ft low-profile under pipe racks
Horizontal extraction, no suspended loads
All-weather operation
Precise bundle manipulation
200 tons
Max Force
0-15 ft/min
Speed
72 in
Max Diameter
60 ft
Max Length
0-3 mph
Travel Speed
14 ft
Work Height
Diesel
Power
Electric
Option
Results
65%
Time Reduction
47
Exchangers
$4.8M
Cost Savings
0
Safety Incidents
Turnaround reduced from 45 to 28 days (17 days ahead). Average extraction time: 6.5hrs → 2.3hrs. Crane rentals ($180K) eliminated. Simultaneous work increased 40%. Zero weather delays during 3 high wind events (42hrs saved).
“Using self-propelled bundle extractor changed how we perform heat exchanger maintenance. Our turnaround moved from a sequential process to a parallel one. We are now planning to use this equipment for all future turnarounds.”
North Sea Platform Achieves Safe Bundle Extraction in Extreme Conditions with Aerial Bundle Extractor
12
Exchangers
$2.3M
Avoided
100%
Uptime
Project Background
Aging North Sea production platform with 12 critical heat exchangers across 3 deck levels. Compact deck layout, limited crane availability, weight restrictions, and narrow weather window. Conventional extraction would require deck modifications and 8 additional days crane mobilization ($2.3M cost).
Challenges
Deck WeightMax 15,000 lbs point loading
ClearanceOnly 9ft at some locations
No CranePedestal crane on drilling ops
Extreme Weather25-45kt winds, -5 to 8°C
Limited POBOnly 18 maintenance crew
ATEX Zone 2Explosive atmosphere cert required
Solution: AE-150 Aerial Bundle Extractor
SelectedAE-150 Aerial Bundle Extractor
Modular design (<4400 lbs modules)
Adjustable outrigger load distribution
180° rotation around obstacles
ATEX Zone 2 compliant
Spill-free hydraulic system
4-hour assembly time
150 tons
Max Force
35K lbs
Max Weight
8 ft
Min Clearance
18 ft
Max Lift
4,400 lbs
Heaviest Module
4 hrs
Assembly
ATEX 2
Rating
IECEx
Cert
Results
12
Exchangers
14 days
Total Time
$2.3M
Cost Avoided
100%
Uptime
All 12 exchangers completed within weather window. No deck modifications required. Operation maintained in 40kt winds (crane limit: 25kt). Personnel reduced 40%. Zero dropped objects or environmental releases.
“The aerial bundle extractor helped us keep on schedule even when weather would have shut down crane operations. Most important, we felt safe working without suspended loads over our deck.”
Southeast Asian Petrochemical Complex Standardizes on Hydraulic Bundle Puller for Annual Maintenance Program
340
Extractions
32%
Cost Cut
99.2%
Availability
Project Background
World-class Jurong Island facility with 200+ shell-and-tube heat exchangers in ethylene cracker, aromatics, and polymer units. Required flexible extraction capabilities for planned turnarounds and unplanned maintenance. Previous contractor/rental model had extreme fluctuations in quality and price.
Challenges
High Utilization8-12 extractions/year, 24hr emergency
Varied Layouts500 to 120,000 lbs bundles
Quality Issues300% productivity variation
Cost Variance40-60% over budget at peak
Tropical ClimateHeat, rain, high moisture
Solution: HP-100 Hydraulic Bundle Puller Fleet
Fleet of 3HP-100 Hydraulic Bundle Puller
Unit 1: Standard, 24/7 central facility
Unit 2: Heavy Duty, 150T ethylene cracker
Unit 3: Compact, 75T polymer unit
24 technicians certified + annual refresher
Quarterly inspections, annual overhauls
4-hour emergency response
75-150T
Capacity
36-72 in
Stroke
72-108 in
Width
12-26K
Weight (lbs)
Results (Year 1-3)
340
Extractions
32%
Cost Reduction
99.2%
Availability
4 hrs
Response Time
32% lower costs than previous model. 45% decrease in average extraction time. Emergency response: 48-72hrs → 4hrs. Zero equipment-related safety incidents (vs 3 prior incidents). Crew competency scores improved 60%.
“Standardizing on a single hydraulic bundle puller platform transformed our heat exchanger maintenance from a reactive, variable-cost activity into a predictable, controlled process. The 32% cost reduction exceeded our business case projections.”
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Resources
More Tools & Calculators
Equipment Comparison Tool
The Self-Propelled Bundle Extractor performance needs to be compared with existing extraction methods to help you select the best option for your facility.
Compare NowTurnaround Time Savings Calculator
The Self-Propelled Bundle Extractor enables you to calculate potential time savings during plant turnaround operations according to your current traditional methods.
Calculate SavingsSelf Propelled Bundle Extractor FAQs
Everything you need to know about Self Propelled Bundle Puller
Operators engage a hydraulic cylinder-amped variable hydraulic drive in order to position the unit, clamp material, and extract bundles from the plant’s storage area. Supported with a carbon-fiber retainer beam due to ease in positioning the machine, the hydraulic clamps and lifting arms have to be operated together by the operator by manipulating the hydraulic lever using their one hand, while their second hand should be free to reach the emergency kill switch at all times during the lifting process.
Operators are capable of using analog controls with joysticks to tune in the precision motion during bundle extraction and they engage in the routine inspection and servicing of the load-bearing hydraulic cylinders.
Yes, self-propelling equipment developers have the capability to adjust clamp geometry, hydraulic stroke lengths, and control software so that the machine can cope with many sizes of load and material.
For the adjustment, the operators may need Exchangeable gripping heads, cold pressure adjustment settings for the load-bearing hydraulic cylinders, and further customization options for the joystick response curves to decide between the safe and effective extraction of different bundle materials.
Extraction machines will have an additional line rupture protection with redundant safety systems in the form of mechanical overload stops on the bogies, pressure relief valves incorporated on any hydraulic circuit, and power-off emergency switches linked with some real-time sensors that monitor for line tension being dropped out all of a sudden.
The integration of such line safety mechanisms with operator controls (e.g., halting joystick action automatically as soon as line rupture occurs) proffers protection against unintentional machine motions while extracting bundles.
Important: We would therefore advise formal training where necessary.
Training Requirements (HLAs)
Operators must obtain on-the-job training for safe joystick operation, while discerning proportional control responses, notification about emergency techniques, including pressing the emergency shut-off switches and the proper sequence for extracting ledges. Such training should be detailed to a certain machine model so that operators familiarize themselves with the concept of holding and movement of the load-holding cylinders of this machine. Additionally, they can learn to react to line break safety alarms triggered for designed hydraulic hoses (114–116).
The basic construction of the bracket should meet the required size and strength. For instance, it should have a clearance for the hydraulic cylinder stroke, plus safety-locking the hydraulic cylinder in the open position when a line breaks for operator safety when switching between panels or performing service work.
The self-propelled instrument must be stable and supported in the two paths to load-bearing bracket mounting. Two shock absorbers, radio noise, and strong impact need to guide the working tool and equipment from rattling.
In reality, the column equipment is subject to rigid control by using the mounting flange with a tapered pin because there are no bored holes into which a pin would be inserted.
In case of failure, the operator is responsible for the immediate emergency stop, an emergency protocol, or temporary holding to strap and secure load-carrying cylinders, assess the partial condition for hazards, and follow the controlled recovery scheme.
The suspended post-incident check includes examining hydraulic systems, which features an introspection phase; tractability and whole joystick are involved, and the machine chunks check.
When customized according to specifications, self-propelled extracting machines can adapt to a variety of environments: providing tires or tracks according to ground conditions, preparing weather-practical controls and enclosures for outdoor environments, establishing clutch and brake settings and configurations on the slope, and implementing the tuning of the attached clamp types for bundles of exposed materials.
Customization also implies adjustments in the joystick sensitivity and the programming of additional safety sensors and/or remote cutoff-switch devices to fulfill specific safety and operational requirements necessitated by the given site.
The self propelled bundle puller of our company has the capability to handle pipe bundles which weigh up to 25000 kilograms and it can pull bundles which reach a strength limit of 50000 kilograms. We produce equipment which can handle loads of 65 tons and 100 tons for demanding operational needs.
Max Bundle Weight
25,000 kg
Max Pulling Force
50,000 kg
Max Diameter
2,000 mm
Max Length
8,000 mm
Heavy-Duty Options
65 & 100 tons
We require your specific heat exchanger dimensions so that we can help you find the correct system capacity.
Our product line includes aerial bundle extractors which we manufacture as part of our complete product range. Aerial units mount on structural supports to achieve optimal height alignment for exchangers on elevated platforms.
We provide both stationary aerial extractors and combination units which can operate in both ground and aerial modes. Our engineering team can recommend the best configuration based on your plant layout and exchanger locations.
- Stationary aerial extractors for fixed installations
- Combination units for ground and aerial operation
- Structural support mounting systems
- Custom height alignment solutions
- Engineering consultation for optimal configuration
Our bundle extractors hold CE certification because they meet all requirements of European Machinery Directive 2006/42/EC. We supply complete technical documentation which includes Declaration of Conformity and user manuals and maintenance guides in English.
Our company provides ATEX certification as an optional service which covers both Zone 1 and Zone 2 hazardous area applications. The equipment delivery package contains all necessary certification documents.
CE Certified
2006/42/EC Compliant
ATEX Zone 1 (Optional)
ATEX Zone 2 (Optional)
Documentation Included
- Declaration of Conformity
- User manuals in English
- Maintenance guides
- Complete certification documents
The hydraulic bundle puller uses multiple design elements to protect tube sheets:
- Guided Rail System — Enables linear extraction motion because it prevents any angular force movements
- Hydraulic Flow Control — Enables smooth pulling operations without any sudden movement
- Load Sensors — Block operators from using more than safe operational limits
- Precision Alignment System — Enables operators to achieve exact cup extraction center points
The features which are combined with the operator training enable extraction without any damage to the equipment even when dealing with heavily fouled bundles.
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