Sarens Contracted for TCO Plant Turnaround Project in Kazakhstan – Heavy Lift News
14 Mar 2024

Sarens Contracted for TCO Plant Turnaround Project in Kazakhstan

The 112t column D 503 was more than 30 years old and lacked a proper lifting lug, which made the operation a challenge for the crew.

The TCO plant in Tengiz, Atyrau, Kazakhstan, contracted Sarens to help with turnaround works at the facility last year. By August 2023, Sarens Kazakhstan had successfully completed all critical work for the turnaround project, including replacing a D-503.2 column, which weighed 112t, and three reactors (R-720, R-721, and R-725) each weighing 56t. Sarens also designed and supported a variety of lifting works for the project, including the installation of transformers and the replacement of hard-to-reach pipelines.

As part of ongoing operations at the site, Sarens used 18 axle-lines SPMT as well as 14 cranes, including a Liebherr LR 1600-2 (600t), Sumitomo-SCX 1500A-3 (150t), and CC2400-1 crawler crane (400t). The Liebherr and Sumitomo cranes were mobilised from Almaty while the other oversized cargo came from Atyrau and Aktau, 427km and 700km away, respectively. They remained on-site and operational for periods ranging from 25 through 60 days, and were configured in SLDB configuration with a 72m main boom and 260t SL counterweight.

As part of the turnaround operation, Sarens was tasked with replacing the most critical element: the 112t column D 503. The column was more than 30 years old and lacked a proper lifting lug, which made the operation a challenge for the crew. To address this, Sarens Kazakhstan and the UK-based engineering team proposed using a needle beam to lift and remove it.

Sarens UK manufactures the needle beam specifically for this type of column, though installing it was still one of the most challenging parts of the operation. One working shift of twelve hours was needed to attach the new lifting tackles to the old column. To remove the old column and install the new one, Sarens then used a lift radius of 38m, completing the lifting work in less than half a day.

The team worked with extreme precision and care as they replaced the column, three reactors, and a variety of other elements. They had to manoeuvre around a narrow and congested working area that included overhead pipelines, trenches, manholes, light poles, and fire hydrants.

Finally, with the lifting work complete, Sarens project engineer Bassarov Kairat said, “Thanks to the professionalism of Sarens colleagues, all difficult tasks were completed on time and safely. This has helped earn more trust and respect from our client, TCO.”

 

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