Transporters and Cranes Facilitate Processing Plant Upgrade
The movement and replacement of process plant components are a familiar sight in the Texas Gulf Coast region — though not often to the scale and timeline faced by one EPC contractor. Per the client's request, the EPC contractor was tasked with the haul and lift of two trains of fractionation tower components (one per train: debutanizer, depropanizer, splitter, and deethanizer) over the course of nine months.
Specifically, the job required the transport of the eight components from the fabricator shop to the job site, on and off barges, and along roadways, including across an interstate.
Multiple pieces of equipment were used for the move, including a 9-axle-line Scheuerle Highway Extendable trailer, two 8-axle-line Goldhofer THP/DL “Dual Lane” transport trailers, and two double-wide 18-axle-line Scheuerle SPMT trailers for over the road transport. Before and during the move, Deep South coordinated traffic control and logistics with multiple organizations.
The lift and set of the components at the process plant would take some additional creativity and planning.
Here are the specifics of the components:
- Depropanizer vessel (519,000 pounds): 660T Liebherr LR-1600/2 full super lift (661 kips) and tailing with 1,800T VersaCrane™ TC-28000
- Splitter vessel (542,000 pounds): 660T Liebherr LR-1600/2 full super lift 661kips and tailing with 1,800T VersaCrane™ TC-28000
- Deethanizer vessel (1,262,000 pounds): 1,800T VersaCrane™ TC-28000 (main 400 kips/aux 960 kips) tailing with 660T Liebherr LR-1600 (441 kips)
- Note: The Debutanizer for train #1 was set by the client.
- Debutanizer vessel (235,000 pounds): 660T Liebherr LR-1600/2 super lift (331 kips)
- Depropanizer vessel (519,000 pounds): 660T Liebherr LR-1600/2 full super lift (661 kips) and tailing client crane
- Splitter vessel (542,000 pounds): 660T Liebherr LR-1600/2 full super lift (661 kips) and tailing with client crane
- Deethanizer vessel (1,262,000 pounds): 1,800T VersaCrane™ TC-28000 (main 400 kips/aux 960 kips) tailing with the 660-ton Liebherr LR-1600 (441 kips)
The depropanizers and splitter vessels were particularly challenging because each weighed over 500,000 pounds, requiring the super lift capabilities of the 660-ton Liebherr LR-1600/2 crawler crane with 661 kips of counterweight as well as the 1,800-ton VersaCrane™ TC-28000 high capacity mobile crane.
The heaviest component was the 185’ long, 1,262,000 pounds deethanizer vessel, which required the VersaCrane™ TC-28000 with the LR-1600. The entire haul and lift job was safely completed within the required nine month schedule.
About Deep South: Deep South Crane & Rigging is a leading provider of heavy lift and transport solutions in the refining, chemical, and energy sectors and strives to provide its customers the best tools to complete the task at hand and is home of the VersaCrane fleet. The firm offers a complete range of services, from bare crane rental to turn-key heavy lift and transport solutions to clients in North and South America. It operates out of 7 locations including Baton Rouge, LA; Sulphur, LA; New Orleans, LA; Dequincy, LA; Beaumont, TX; Houston, TX; and Catlettsburg, KY. Sister company DS Americas operates out of Bogota, Colombia. Recent recognition includes 2018 Houston Business Roundtable (HBR) Best of the Best Safety Excellence Award, 2019 Mentor Award, and 2020 Finalist; 2018 Industrial Safety Training Council (ISTC) Safety Achievement Award; 2018, 2020 and 2021 Greater Baton Rouge Industry Alliance (GBRIA) Contractor Safety Excellence Award, Crane & Rigging; 2019 Greater Baton Rouge Industry Alliance (GBRIA) Workforce Development Best of Division OneAward; 2018, 2019, 2020, and 2021 Specialized Carriers and Rigging Association (SCRA) Safety Award; 2018, 2019, 2020 and 2021 Louisiana Worker's Compensation Corporation (LWCC) Safest 70); 2021 Texas Mutual Platinum Safety Partner Award; and 2021 Safety Council of Southwest Louisiana (SWLA) Silver Level Contractor Safety Performance Award.
Creative Thinking Keeps Transport Costs Low and Delivery Quick
As part of a natural gas fractionation project, an EPC contractor needed to transport two large drums to the customer’s facility. The hot oil drum (59’8”L x 17’6”W x 23’3”H) weighs 186,400 pounds and the suction KO drum (53’8”L x 21’W x 21’ H) weighs 222,034 pounds.
Many Lifts, One Solution: Module Lift System Flexes Hydraulic Muscles During Process Plant Overhaul
Deep South crews were challenged to haul, lift, and set 84 modules, including three towers (one measuring 100’ long, 350,000 lbs.), as well as various pieces of process equipment, such as piping, tanks, PDC buildings, and transformers—all within a tight schedule. Many of the modules had offset centers of gravity further complicating the lift and set.