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Heavy Lift

Hydro Deck’s one-of-its-kind design enables efficiency for offshore windfarm project

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Hydro Deck’s one-of-its-kind design enables efficiency for offshore windfarm project. Image: Mammoet
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Its task was to transport a 5,000t offshore substation topside and a 1,500t reaction compensation station topside from Batam, Indonesia to Singapore.

Hydro Deck’s large cargo surface area (5,600m2) allowed Mammoet to hold the two topsides and transport them in a single trip. This reduced the necessity to perform operational work more than once.

Combining Hydro Deck’s rapid ballasting system capacity with the flexibility of having roll-on/roll-off ramps on both the bow and stern of the barge, Mammoet minimized movement and rotation of the Hydro Deck. This was crucial because the operational period saw high sea traffic at both Batam and Singapore shipyards.

For this project, Mammoet redesigned the mooring arrangement by installing four additional mooring winches and eight roller fairleads on the Hydro Deck. This meant the barge did not need to be rotated, with load-in and load-out performed from either the bow or stern side.

Using a minimal number of maneuvers, the team was able to perform the load-in and load-out efficiently, maintaining the high safety standards required by the shipyard, while accommodating the reduced space available due to high sea traffic. A close eye was always kept on safety; by ensuring the rapid ballast system capacity met standards, and through maintenance on the system taking place on a regular basis, sharing updates with the client.

Besides the use of Hydro Deck as an interim barge, Mammoet supplied many services as a single point of contact. These included barging, weighing, mooring, ballasting, towing, tug management, plus load-out and load-in using 200 axle lines of SPMT.

Mammoet’s complete solution enabled the transportation of the topsides in one single journey.

The Hydro Deck is a floating pontoon developed in collaboration with AG&P for a range of operational needs in locations with extreme tidal variations. It increases the efficiency of operations where port facilities are less available or – as here – rapid ballasting is a key consideration.

Heavy Lift

Sarens lifts and installs 67 wind turbines at Norwegian wind farm

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Sarens lifts and installs 67 wind turbines at Norwegian wind farm. Image: Sarens
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Sarens expertise in the wind energy sector has been an asset in helping clients like FairWind and Siemens Gamesa erect several wind turbines at a Norwegian wind farm in Kvitfjell Raudfjell. Beginning in August of 2019, Sarens was on site to see the project to completion.

Equipment

The following teams and equipment were deployed to carry out the operation:

The first main team used an LG 1750 SX in SL22 configuration with 105-metre boom and 250-tonne counterweight; an AC 220-5 auxiliary crane for tailing the WT components; and an Explorer 5500 as a second auxiliary crane for relocating the main crane.

The second main team used an LG 1550 in SL configuration with 98-metre boom and 200-tonne counterweight; an AC 200 auxiliary crane for tailing the WT components; and an Explorer 5500 as a second auxiliary crane for relocating the main crane.

The third preassembly team used an AC 500-2 in HASSL configuration to assemble the first two tower sections and an Explorer 5500 auxiliary crane for tailing and relocating the 500-tonne crane.

“In the beginning, there was only one main crane: the LG 1750,” says project manager Adam Kopaczewski. “After three months, the client decided to order one more main crane team, and from November 2019 onwards we also had the LG 1550 and AC 200 as a second main team.”

An advantage of using the LG 1750 and LG 1550 cranes was that they did not need an SL for assembling this particular type of wind turbine at a worksite difficult for crawler cranes to manoeuvre. The wind farm is located on a mountaintop, and when relocating crawler cranes from one pad to another, the crew would have had to completely disassemble them. This is why Sarens opted for mobile lattice boom cranes, saving considerable time when moving cranes.

Rigging

All cranes arrived via special vessel and were unloaded 40 kilometres away from the project site, at Tromso harbour. Then, Sarens transported the crane components to the site via truck. Assembling the cranes proved challenging: Sarens had to use a special container to support the main boom because the level difference between the main crane’s hardstand and the boom assembly area was sometimes as great as 10 metres.

Execution

The Sarens crew lifted all wind turbine components, including three tower sections, the nacelle, the generator, and full rotor. The largest load was the nacelle and generator, which weighed 103,5 tonnes!

Aside from the terrain, weather was the biggest challenge the crew faced. From November through April, the worksite was covered in snow as deep as seven metres in some areas. Meanwhile, wind speeds sometimes reached almost 40m/second.

Nevertheless, the crew worked tirelessly to complete this project. Working in two nine-hour shifts, they lifted each of the wind turbines in place. The team included several crane drivers, ten riggers, five truck drivers, and two site managers. Sarens would like to congratulate each of them for their tireless effort and dedication to this important project.

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Heavy Lift

Sarens completes installation work at Alberta, Canada gas plant

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Sarens completes installation work at Alberta, Canada gas plant. Image: Sarens
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Sarens recently completed Phase II expansion work at the Wapiti Gas Plant, a liquid handling and gas processing facility in Grand Prairie, Alberta, Canada. This included installing modules, towers, and vessels on behalf of the project owner, Keyera Partnership. The project began in July of 2019 and finishes in April of 2020.

To complete the installation work, Sarens deployed the following equipment:

  • 1x Demag AC 500-2
  • 1x Liebherr LTM 1400-7.1
  • 3x Tadano GR 1000XL
  • 1x National 30100C
  • One prime mover
The large ATs came out of Europe through the Port of Halifax, then via rail into Edmonton, and finally on low-bed transport to the site, which took several weeks.
“The remote site location, along with weather and road conditions, affected access,” says project manager Drew Ferris. “Due to heavy rain over the summer and fall months, the roads and site were mostly deep mud.
”Because the project site is located approximately 40 kilometres down a haul road and an hour away from the nearest town, Sarens was required to coordinate among multiple parties to ensure delivery timelines and schedules were met. One of the biggest hurdles, however, was the uncertainty of rail delivery schedules, which postponed the arrival of both cranes.
Once on site, the cranes were assembled and annual structural inspections completed so that work could begin. Both the AC 500-2 and LTM 1400-7.1 made significant lifts in excess of 100 tonnes, and performed flawlessly under the control of experienced operators and supervisors. T
There were 40 critical lifts planned and executed on site, ranging from 3m x 3m equipment skids weighing 9 metric tonnes to 23m x 6m process skids weighing 108 tonnes. The project consisted of two main units for the expansion, and as Sarens installed equipment the units gradually became smaller, which required that special attention be paid to swing radii and clearances. As a result, the crew moved all the cranes around on a regular basis.
Sarens completed the heavy lift package with a contractor tower measuring 3 metres wide and 27 metres tall, and weighing 188 tonnes. This was installed with the LTM 1400-7.1.
Because work took place in an operational gas plant, it required H2S Alive training. At the project’s peak, Sarens had two supervisors and eight operators working on a three shift rotation.
Sarens is proud to have been involved in this important project and commends everyone involved on their valuable contributions.

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Heavy Lift

Konecranes hybrid RTGs to Norfolk Southern in the US

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Konecranes hybrid RTGs to Norfolk Southern in the US. Image: Konecranes
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Konecranes has been selected by US Norfolk Southern Corporation (NSC) to provide five Konecranes hybrid RTGs for intermodal operations in the Chicago area. The order was booked in December 2019.

Konecranes RTGs are known for their reliability, productivity and eco-efficiency. Now Norfolk Southern Corporation will become a Konecranes RTG customer, ordering five Konecranes hybrid RTGs. The hybrid RTGs are equipped with a battery pack and Tier iV final genset for very eco-efficient operation.

Alan Garcia, Sales Manager Americas, Konecranes Port Solutions, said: “This is a substantial vote of confidence from Norfolk Southern in our RTG technology. Our Powered by Ecolifting approach, which is seen here in the hybrid packs that power the machines, will deliver great eco-efficiency in support of Norfolk Southern’s commitment to sustainable business practices. We will ensure that Norfolk Southern is entirely satisfied with the performance of these state-of-the-art hybrid RTGs and how we support them.”

“Konecranes was awarded the business because of the technical capabilities of their RTGs, and because of feedback received from current Konecranes customers regarding the quality and service support they’ve received. Norfolk Southern is committed to increasing productivity and fuel efficiency at its Intermodal terminals,” noted Brandon Smith, AVP Customer Operations at Norfolk Southern.

Norfolk Southern Corporation is one of the premier transportation companies in the US. Its Norfolk Southern Railway Company subsidiary operates approximately 19,500 route miles in 22 states and the District of Columbia, serving every major container port in the eastern US and providing efficient connections to other rail carriers. It is a major transporter of industrial products, including chemicals, agricultural products, and metal and construction materials. In addition, the railroad operates the most extensive intermodal network in the east and is a principal carrier of coal, automobiles, and automotive parts.

Powered by Ecolifting is Konecranes’ vision to reduce the footprint and increase the handprint of equipment for container terminals. From eco-optimizing diesel drives to hybridization and fully-electrified fleets, we will continue to do more with less.

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