Champion Reactor for Tuapse Refinery

Champion Reactor for Tuapse Refinery
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Our magazine already described the unique operation on delivery of hydrocracking reactors batch for Tuapse Oil Refinery (OAO Rosneft). Today we are publishing new details of this transport operation which is a real milestone event for our country.

Transportation of these reactors from Izhorsky Zavod shop to the jetties in Ust-Slavyanka settlement with further Ro-Ro loading on barges was managed by Keen-Mark Group as two batches. Shipment included a total of two hydrocracking reactors weighing almost 1,400 tons, more than 40 meters long and more than 7 meters in diameter each, as well as four 600-ton reactors and two measuring over 29 meters long, two – over 25 meters and all four – more than 7 meters in diameter. Total weight of carried equipment exceeded 5,000 tons.

According to A.K. Lindstrem, Keen-Mark Group Project Department Manager, this operation was challenging, as it was required to transport three extra heavy reactors at a time. Therefore, Keen-Mark Group used three own module combinations.

Overall, 96 axle lines SCHEUERLE and GOLDHOFER and two ballast rigs Mercedes Benz Titan were involved in this transport. A combination of SCHEUERLE SPMT was used to haul the reactor with cradles weighing 1,386 tons: 48 twin axle lines which, due to its width of 5,330 mm, ensured stability to avoid tipping of the load with a very high center of gravity. Two 350-kW power packs created the required tractive force and uninterrupted operation of steering system. Total weight of the haul combination made over 1,500 tons.

Two haul rigs GOLDHOFER THP SL/PST with 16 axle lines and a 1+1/2 combination (the so-called “split” combination) were used to transport the 600-ton reactors. The first rig is self-propelled, with a 155-kW power pack, the second one – a conventional trailer with trailer hitches from both sides and two 4×4 prime movers Mercedez Benz Titan developing 550 h.p. each. Also involved: a backup tractor unit, support vehicle, two escort vehicles.

Distinguishing about modular vehicles is the possibility to change moving direction keeping all the technical features. This allowed to change the number of directions enroute whenever needed and get the load on the barge in the required position.

The transport was preceded by long preparations, when Keen-Mark Group took significant efforts to modify the road along the route, remove overhead power lines, communication lines, eliminate existing obstacles (fences, poles), prepare the transport design and have it approved by all monitoring bodies.

Difficulty of the haul was caused by the fact that the route also passed through narrow roads on the territory of Izhorsky plant, dirt process road, as well as public city roads with high traffic density and turning constraints.

The most complicated and key moment of this transport was passing the temporary railway crossing for high-speed Sapsan trains which happened at night. The time window for the 3-vehicle convoy driving through the crossing after its arrangement was just 20 minutes. Even a slight delay of passage could result in a train schedule breakdown which was absolutely unacceptable. Eventually, the convoy of three rigs with a total length of 200 meters smoothly passed the crossing in due time.

“All this machinery wouldn’t have demonstrated its potential without skilled drivers and operators of Keen-Mark Group,” noted A.K. Lindstrem. Each rig was attended by a team of 4-6 people, including operators and drivers. Most of personnel were repeatedly trained at manufacturers’ locations, the specialists have appropriate qualification which is backed up by certificates.

The transport route extension was 14 kilometers. As per the schedule of passing railway crossings and shipping technology, in accordance with which the travelling speed did not exceed 2 km/h, it took 5 days to deliver each batch. A road traffic safety project was developed implying installation of temporary road signs, imposing restrictions and change of traffic plan, and involving up to eight Road Patrol Service cars.

Rolling of the 1,000-ton equipment onto the barges of North-Western Shipping Company provided by ZAO Infotech Baltika was ongoing for two days. The way the equipment shall drive onto the barge was designed by ZAO CNIIMF. The barge was fixed on specially prepared bedding, and stage by stage, the haul rig was making moves progressively as the barge ballast was pumped out and taken in. The item was taken off the rig using its hydraulic system by means of lowering the reactor with cradles onto dedicated prepared stools.

The transport of the reactors from St. Petersburg to Tuapse was in progress from August 10 till November 16 in two stages and became a significant event for the Russian project freight market: never before had the equipment with such weights and dimensions been shipped along the RF inland waterways. The shipping involved four tugs and two barges of OAO SZP which made four trips. Chartering management was led by a company’s subsidiary – OOO Volgo-Baltic Logistic.

Thanks to well-coordinated teamwork of Keen-Mark Group specialists and OAO SZF ships crews, the cargo was delivered to unloading point in the city of Tuapse before the closure of navigation period on inland waterways.

“It is worth mentioning that in parallel to this project, Keen-Mark Group was busy with several more projects in various regions of Russia,” says Lead Manager of Project Department – D.G. Galkin. – Owing to increasing number of orders and extension of geography of company’s activities, we have decided to purchase 40 Scheuerle SPMT axle lines. This will allow the fleet of company’s self-propelled axles to be increased to 88 pcs by the summer of 2013, which, in its turn, will enable shipping of non-divisible loads weighing up to 3,500 tons.”