When our client – a leading processor and exporter of refined copper and precious metal by-products – decided to replace the plant’s decommissioned heat exchange vessels, they contacted The Men From Marr’s for a heavy lift craneage solution that could be completed safely within a scheduled shutdown and without disruption to operations.
Working over a live refining and smelting plant with limited space, during a scheduled shut down – the question was how quickly and safely can we turn this around with as little disruption to operations as possible?
Employing the Marr Crane Mat System and one of our Marr 2480D tower cranes to dismantle the structures in large manageable pieces (weighing up to 180t), our approach minimised the risks associated with working at height with limited space on the ground.
With less lifting and a quicker deconstruction program, the overall risk on the project and to plant operations was reduced. Our solution allowed the refinery to return to production earlier than originally planned.
The original crane methodology proposed using a 600-tonne crawler crane with a super lift attachment which would have required demolishing part of the plant and shutting down critical production. The project proposed a number of challenges including working to a scheduled shutdown program in a congested site with restricted space and significant underground services. The areas highlighted in red above indicate structures that would have had to be demolished for the 600-tonne crawler crane to operate, subsequently ruling the original methodology out as a viable option.
Using the Marr Crane Mat System, one of our M2480D Heavy Lift Luffing (HLL) tower cranes could be installed on an above ground 10x10m static base off the existing roadway in an area inaccessible to traditional craneage solutions.
The heavy lifting capacity of Marr’s 2480D HLL – rigged to have a capacity of more than 280 tonnes – allowed the decommissioned vessels to be removed in a single lift and moved to the roadside for removal by road transport.
After the old vessels were removed, new replacement vessels were installed using the same crane configuration.
The last replacement vessel was installed with the 12-week scheduled shutdown resulting in the project being completed with less lifting, reduced risk to plant operations and a substantial cost benefit over the original planned methodology.
The methodology used on this project can be adapted for any large-scale operation where there is limited space to work at the interface of other working fronts, and a similar need to avoid non-scheduled shutdowns of operations.
Let's talk about how we could add value to your project
We work with our clients to find a solution that works – no matter how big or complex the job is. And if the right crane doesn’t already exist, we’ll build one to suit the needs of your project.