mammoet insight · 2019-09-06 · at mammoet, we provide solutions for lifting, transporting,...

At Mammoet, we provide solutions for lifting,

transporting, installing and decommissioning

large and heavy structures.

We could talk for hours about the equipment we use,

and about how sophisticated and powerful it is.

But all that power means nothing without a plan.

In fact, we believe our business isn’t about size.

It’s about: time.

Uptime. Turnaround time. Time to market. To our

customers, time is the currency that matters most.

That’s why we strive to bring their deadlines forward.

It’s an integrated, daily effort shared by everyone

at Mammoet.

That’s how we move time for our customers.

So time isn’t set in concrete. Or forged in steel.

It’s not even all that heavy.

And yet, it’s the biggest thing we can move for you.

Discover more on www.mammoet.com

At Mammoet, we provide solutions for lifting,

transporting, installing and decommissioning

large and heavy structures.

We could talk for hours about the equipment we use,

and about how sophisticated and powerful it is.

But all that power means nothing without a plan.

In fact, we believe our business isn’t about size.

It’s about: time.

THE BIGGEST THING WE MOVE

IS TIME

Untitled-1 1 01-04-15 09:28

NUCLEARPOWERPLANTS

MAMMOETINSIGHT

HISTORY

PLANNING & DESIGN

LOGISTICS

CON-STRUCTION

OUTAGES

DECOM- MISSIONING

PROFILE

MA

MM

OE

T IN

SIG

HT N

UC

LEA

R P

OW

ER

PLA

NTS

MAMMOET INSIGHT | NUCLEAR POWER PLANTS2

IN THE BEGINNING

The electric light bulbs shown in this image are the first known use of electric power from atomic energy. The bulbs were lit by electricity from the generator on the right. The generator operated using heat from the experimental ‘Breeder Reactor 1’. On December 20 1951 the generator was turned on for the first time, lighting these four 200 watt bulbs. Later one of the bulbs was presented to President Harry S. Truman. This historic experiment took place at the Atomic Energy Commission’s National Reactor Testing Station in Idaho. The reactor power plant went on to supply all the electricity for the building in which it housed.(AP Photo)

shown in this image are

The generator operated

generator was turned on for the first time, lighting

experiment took place at

Reactor Testing Station

supply all the electricity for the building in which

The electric light bulbs

3 4

6

9

7

6 MAMMOET MIDDLE-EAST

Office: Dubai, United Arab EmiratesTelephone: +97 14 812 8000E-mail: [email protected]

7 MAMMOET ASIA-PACIFIC

Office: SingaporeTelephone: +65 6861 1638E-mail: [email protected]

8 MAMMOET LATIN-AMERICA

Office: São Paulo, BrazilTelephone: +55 11 4440 0333E-mai: [email protected]

9 MAMMOET SOUTH-AFRICA

Office: Johannesburg, South-AfricaTelephone: + 27 11 882 4499E-mail: [email protected]

NUCLEAR POWER PLANTS | MAMMOET INSIGHT 3

FOREWORD

On December 20, 1951, light bulbs were lit by nuclear energy for the first time. This happened at Argonne National Laboratory, a US national research center. Since then, around 440 civil nuclear power reactors have become operational in the world, providing approximately 11% of the world’s electricity.Global population and economic growth have a significant impact on energy demand, providing stimulus to the nuclear power industry. Some 60 plants are currently under construction. They will add a non-carbon based, reliable source of capacity to the global supply of energy. Plant owners and operators are focused on the highest safety standards while seeking ways to increase cost effectiveness and operational efficiency to aid competitiveness.Since the early 1970’s, Mammoet has been heavily involved in the nuclear industry – we have provided services for the construction or maintenance of around one in five plants that are currently operational. We have proven experience, in a sector which requires the highest safety and operational standards. This unparalleled track record in nuclear projects makes us world leaders in our field.We believe that engineered heavy lifting and transport services can help the nuclear industry increase cost effectiveness at each phase of a plant’s life cycle – from planning through to decommissioning. This can be realized through smart approaches that bring commissioning dates forward or streamlined ways of working that avoid delays. This magazine aims to demonstrate how our expertise and insight could contribute to improving the economic viability of civil nuclear plants as well as their safe construction and operation.We hope you enjoy reading it. Should you want to discuss any of the content or share your thoughts, ideas or feedback, we’re happy to take your call!

Best regards, on behalf of Mammoet,

Jan KleijnChief Executive Officer


CONTENTS

20CONSTRUCTION

HELPING TO CONSTRUCT THE FUTURE OF NUCLEAR POWER

24 FOLLOWING A SMOOTH CURVE TO INSTALLATION

26 BUILDING AN ARCH TO STAND THE TEST OF TIME

16LOGISTICS

TAKING CARE OF THE CRITICAL PATH

19 SOMETIMES THE SAFEST SOLUTION IS ALSO THE FASTEST

12PLANNING & DESIGN

PROJECT OPTIMIZATION THROUGH PLANNING

14 MANAGING RISKS THROUGH DETAILED PLANNING

06HISTORY

A STRONG FUTURE BUILT ON A SOLID PAST

08 MAMMOET DELIVERS

10 NUCLEAR EXPERIENCE SPANNING MORE THAN FOUR DECADES

A


34DECOMMISSIONING

JOURNEY’S END – SAFE AND SECURE

37 NUCLEAR DECOMMISSIONING THROUGH A BOTTLENECK

38 MAMMOET HANDLES A 2,000 TON PROTOTYPE NUCLEAR REACTOR

MORE...46 EQUIPMENT

49 NUCLEAR REFERENCE LIST

50 GLOBAL PRESENCE

40PROFILE

CREATIVE ENGINEERING, CAREFUL PLANNING AND SAFE DELIVERY

44 MINIMIZING DISRUPTION BY THINKING BIG

45 CREATIVE ENGINEERING AT THE BOTTOM OF THE SEA

28 OUTAGES

INNOVATIVE APPROACHES TO SAFELY CUT DOWNTIME

32 IN AND OUT OF THE HATCH

33 INNOVATIVE EQUIPMENT UNLOCKS TIMESAVING METHOD FOR REACTOR REPLACEMENT

Z

Mammoet Insight, 2017

Comments and contributions can be sent to:Mammoet Holding B.V.Marketing & Communication Dept.P.O. Box 100003505 AA UtrechtThe NetherlandsE-mail: [email protected]

© 2017 Mammoet

ConceptMammoet

Graphic designMarc van Meurs, Richard Ottema

LithographyGrasboer Grafimedia, Amsterdam

PrintBadoux BV, Houten

Editing and production teamYvette Bakker, Michel Bunnik, Maurits Croon, EricaGray, Theo Kroese, Paul Schilperoord

TextErica Gray, Paul Schilperoord

PhotographyMammoet, Michael Bergmann

IllustrationsMammoet, Rhonald Blommestijn


Our track record in the nuclear industry is what sets us apart. No other company can offer the experience, equipment and engineering expertise of Mammoet.

A STRONGFUTURE

BUILT ON A SOLID PAST

HISTORY


As a global company with Dutch roots, we are proud of the Netherlands’ engineering legacy. This reputation for delivering projects

safely and on time stems from a practical, ‘can do’ attitude. At Mammoet, we have combined that with our professional discipline and taken it all across the world, wherever we work.

UNSURPASSED EXPERTISE

One of our most notable nuclear projects was the raising of the Russian Navy’s nuclear submarine, the Kursk, in 2001. Our ability to swiftly mobilize expertise for such a dangerous and delicate operation brought worldwide attention to our engineering and project management skills. But our involvement in nuclear projects extends back

further, to the early days of nuclear energy. Since the emergence of the first nuclear power plants, we have demonstrated our ability to meet the strictest of safety regulations. First and foremost, it is our team of professionals who combine a focused attitude, with planning, logistics, engineering and execution skills. Combined with our worldwide network and fleet of state-of-the-art equipment, we have been safely delivering nuclear projects for more than four decades. This has provided us with unsurpassed expertise in nuclear construction, outages and decommissioning. At the same time, we have found ways to improve efficiency and cost-effectiveness for the nuclear industry. Often finding ways to bring deadlines forward or even make up for time lost in other phases of the operation.

MAMMOET DELIVERS“ Mammoet delivers high levels of service and works in a planned way, keeping safety as the number one priority. We know we can always count on Mammoet.”OLIVIER FRELAND, NEW CONSTRUCTION DEPARTMENT HEAD, AREVA


“ I would like to extend a very well earned thank you for your support in the handling and the delivery of our Replacement Once Through Steam Generators at the Crystal River Site. Babcock and Wilcox Canada is very impressed with the overall performance of Mammoet USA regarding this delivery to our customer.”TED WILKEN TRANSPORTATION CONTRACT MANAGER, BABCOCK & WILCOX CANADA

MAMMOET DELIVERSENGINEERING FOR NUCLEAR PROJECTS

Our team of expert engineers are called upon to advise clients on the engineered heavy lifting and transport requirements of every stage of a nuclear plant’s lifecycle. Their comprehensive perspective enables us to come up with engineering solutions to complex technical and logistical problems. Which is what our engineers thrive on – the excite-ment of finding new ways to execute projects more efficiently, safely and effectively.

SAFE EXECUTION

There is a military-style precision to our project planning, execution and process documentation. This provides peace of mind as it demonstrates comprehensive oversight and control of each stage of the operation. Our team of experts understands the specialized transport and lifting operations

required for nuclear projects. Their knowledge and problem-solving skills have been honed through years of working on a wide range of nuclear pro-jects. From installing a reactor pressure vessel at Ringhals in Sweden in 1972 to the 2016 operation to safely enclose the damaged Chernobyl reactor.The involvement of our unique knowledge base, especially at the early stages of a project, enables clients to get the best out of their plant and project design. By tapping into our experience with the whole of a plant’s lifecycle, plant owners and oper-ators benefit from an unrivalled practical perspec-tive on how to make their projects a success. Furthermore, our ability to combine careful plan-ning, innovative engineering and safe execution helps our clients meet, or even beat, their dead-lines. Reliably ensuring their projects are delivered safely and on time. ■

INTRODUCTION


1972Ringhals, Varobacka, SwedenInstallation of reactor pressure vessel Mammoet’s first nuclear experience

1974Iberdrola Cofrentes, Valencia, SpainInstallation of reactor pressure vessel

2004Westinghouse, Doel, BelgiumSteam generator replacement

1979Chooz A, EDF,

Ardennes, FranceTransport of reactor

pressure vessel

2002Tihange 1, Electrabel, Liège, BelgiumSteam generator replacement

1997St Lucie, Florida, USASteam generator replacement

2005Lungmen, Fulong

Beach, TaiwanInstallation of reactor

pressure vessel for Reactor 1 & Reactor 2

2006Watts Barr, TVA, Tennessee, USASteam generator replacement

NUCLEAR EXPERIENCE

SPANNING MORE THAN

FOUR DECADES


HISTORICAL TIMELINE

2011LaSalle, Exelon, USAFleetwide transformer exchange

2012 – 2016Chernobyl Safe Confinement, Chernobyl, UkraineLifting and skidding of confinement arch

2015AVR Julich, North Rhine-Westphalia, GermanyDecommissioning of prototype pebble-bed reactor. Removal of reactor pressure vessel

2016Ringhals, Varobacka, SwedenGenerator replacement

2007 – 2015Olkiluoto 3, TVO, Olkiluoto Island, FinlandConstruction of civil works reactor building. Delivery and installation of reactor pressure vessel and steam generators

2008Angra dos Reis, Electronuclear, BrasilExchange of two steam generators

2009Crystal River 3,

Duke Energy, Florida, USATransport and

exchange of steam generators

2010Three Mile

Island, Exelon, Pennsylvania, USA

Exchange of two steam generators


PROJECT OPTIMIZATION THROUGH

PLANNINGPLANNING & DESIGN

Involving engineered heavy lifting and transport expertise at the start of a project enables optimization of the design of the plant, its components and the project delivery.


For nuclear projects there are impor-tant safety and environmental con-siderations and stringent licensing requirements; it is absolutely essen-

tial to manage out as many risks as possible with thorough and extensive planning. Care-ful consideration at the planning stage con-tributes to a smooth running project path and reduces risks. This helps to bring commis-sioning dates forward, lower capital expendi-ture and render future outage projects – e.g. for steam generator replacements – safer and more efficient.

OPTIMIZATION

Different plant designs and different route designs have an impact on costs and risks for the overall project, particularly on the logistics and construction phases of the project. As a result, the engineered heavy lifting and transport sector can play a sig-nificant role in adding value to nuclear pro-

jects in their planning stages. There are many ways to do this: through providing cost analysis of different designs and route options; assistance with documentation; discussions of creative engineering solu-tions to problems identified at the planning stage. This input optimizes the design of the plant, its components and the project delivery.

EARLY COLLABORATION

It is therefore important for construction engineers to collaborate with engineered heavy lifting and transport specialists at an early stage of the project. Together, sharing respective expertise and experience, it is possible to find the best methods of approach and, furthermore, find solutions to possible challenges.A thorough analysis of all possible routes and installation methods is required to find the optimal solution for the project. It is neces-

sary to identify the potential obstacles and bottlenecks in the transport and installation activities in order to find ways to reduce risks, minimize costs and save time.An experienced engineered heavy lifting and transport partner can assist by identifying such obstacles early in the process and developing solutions to overcome them. By finding alternative routes, methods and tech-nologies there are many opportunities for project efficiencies to be identified and safer methods of transport and installation to be devised.Thorough project planning, including route surveys, enables transport solutions to be designed which overcome logistical chal-lenges along the route or in the installation process. It is also essential to have the ne cessary paperwork – from safety licenses to work permits and traffic regulation compli-ances – accurately prepared and in place well in advance of the project execution. ■


PROJECT PLANS AND PLANT DESIGNS NEED TO CONSIDER:

M ammoet’s experience in nuclear power projects can provide essential insight into the areas requiring

most care and the risks which need detailed management. Transport and installation plans hinge on a number of factors which need consideration to get components delivered to their new location safely and on time. For plants using pre-assembled or standardized parts the planning stage is essential to opti-mize the parts’ design. For other construction approaches optimization of the entire chain of activities required to transport and install components can realize significant safety and operational benefits.

Over forty years of working on nuclear plant construction, outages and decommissioning projects gives us a unique insight into the potential issues our clients may face as well as the opportunities for greater efficiency and further risk reduction. Mammoet provides expertise in the planning stages to identify bottlenecks and obstacles. It is then possible to provide alternative, costed, solutions to those issues so our clients can make informed decisions. We believe that 90% of a project’s success is realized in the preparatory phases. Taking time at the planning stage to carry out thorough route surveys and consider all the possible site constraints, avoids unnecessary delays later in the process and may even move deadlines forward. ■

OPTIMIZATION OF DESIGN THROUGH CONSULTATION

EXPERT INSIGHT

Edvinas Ivanauskas is the General Manager of Mammoet Baltic. He has experience in site preparation, logistic activities and new project development for nuclear power projects dating back to 2008. Since 2013 he has been part of the Mammoet team responsible for the Baltic region and covering nuclear activities in Europe. Here he outlines the value of planning for the overall optimization of the project.

Optimum design of plant and components. For that, the techno-logical lifting and trans-portation possibilities need to be taken into account. Engineered heavy lifting and transport expertise can assist with assessment of the necessary scale and capabilities of equipment and offer a wide range of optimiza-tion possibilities.

Site constraints in terms of weather, environmental issues, permits and safety issues.

Labor constraints: availability, skills, rates and productivity.

Site accessibility, as determined by: elevations, laydown areas, heavy lift footprint constraints.

Transport routes, to identify potential physical constraints: power lines, bridges, roads, turning circles etc. Different national rules and regulations

on the dimensional limitations need to be taken into account.

Available yards or possible alternatives.

Material loading and unloading facilities.

Alternative routes and the cost implications of different transport chains.

Throughout the planning process safety has to be the main priority.


Experienced, reliable and efficient logistics are vital for the safe transport of specialized nuclear components. Expert advice can help identify optimal routes and different modes of transport to

ensure these delicate but large and heavy loads arrive safely,

in the right order and on time.

TAKING CARE OF THE

CRITICAL PATHLOGISTICS


Shipping of oversized and heavy cargo requires specific expertise, as infra-structure limitations create bottle-necks that demand alternative

transport approaches. An optimal route must be developed, often consisting of a chain of differ-ent transport modes. This involves a number of handover points, which require close coordina-tion to minimize delays and reduce safety risks. Often, there is the complexity of switching between different modes of transport: overland, water-based transport and through difficult con-ditions such as artic or desert environments. In addition to this, especially in case of cross bor-der transports, all essential paperwork must be handled.

FACTORY-TO-FOUNDATION

A factory-to-foundation (FtF) service combines the expertise of managing complex logistics with specialist skill and insight in handling heavy and oversized cargo. This delivers a tailor-made and optimized logistic chain, especially in cases where infrastructural limitations rule out stand-ard routes.A FtF service can reduce safety risks, improve construction efficiency and avoid delays. The delivery of the key components to the facility and their installation are always on the critical path of any nuclear project. Optimization of all logistics, including a thorough safety assess-ment, reduces risks and brings about the best possible construction schedule. ■

EXPERT INSIGHT

The transport of oversized and heavy com-ponents for the nuclear industry requires a profound understanding of the project’s

specific transport and safety needs. This comes with experience. Dealing with different customs, regulations and paperwork across a variety of countries and different modes of transport requires careful management. All the transition points must run seamlessly, bottlenecks need to be effectively and safely managed. An integrated and detailed plan for all engineered lifting and transport needs contributes to greater safety, significant efficiency gains and greater cost effectiveness.

Mammoet has longstanding, broad and diverse hands-on experience with all transport modes. We have extensive knowledge of trans-port regulations in countries around the globe and long-standing relationships with the relevant transport agencies. We own the widest and most modern range of equipment available for lifting and transport. For transport on water we have access to a fleet of ships and for inland logistics we have an extensive, global fleet of vehicles and specialist trailer equipment. Our experience with different modes of transport is incorporated into reliable and efficient logistics.

Our equipment’s strict maintenance programs ensure reliability and safety. In specific cases where we do not have our own equipment availa-ble, we can rely on a worldwide and well tested network of partners. If needed, Mammoet offers storage and transshipment services through our own or third party terminals. And all this with one purpose in mind: to achieve uptime of the plant without delays and as safely as possible. ■

AN INTEGRATED APPROACH TO LIFTING AND TRANSPORT

Sales manager for Mammoet Logistics, Lars Lamet, has spent the last 15 years working for Mammoet’s commercial departments, including for the fossil and nuclear energy markets. He is an exponent of the factory to foundation approach to nuclear projects, here he explains why.

“ At all times Mammoet’s involvement was professional and meticulous, their participation assured our customers that the lift was to be carried out correctly and safely by outstanding tradesmen and engineers. We look forward to working with Mammoet in the future.”GARY TOMLINSON PROJECT MANAGER, SHEPLEY ENGINEERS LTD, SELLAFIELD PIPE BRIDGE INSTALLATION PROJECT


SELLAFIELD • CUMBRIA • UK CASESTUDY

Safety was the top priority for the modular construction of a new evap-orator unit at the Sellafield nuclear

reprocessing site. Eleven modules had to be transported to the site before being lifted and installed inside the unit. Mammoet devised a tailormade four-way gantry sys-tem which delivered precision, safety and saved two months of construction time.The gantry system lifted each of the mod-ules safely and precisely to the correct height, from which they could be skidded into the new unit and installed. Because the modules needed to be installed in 11 differ-ent locations in the unit, the entire gantry system had to be moved prior to each installation.Normally, a gantry is jacked-up and down when it needs to be repositioned. Mammoet

came up with the idea of designing and installing the system on permanent skids to save time. This solution greatly increased the level of efficiency, saving two months of time.The modules – ranging between 50 and 500 tons – were built at Ellesmere Port near Liverpool. After completion, they were trans-ported to the quay on Mammoet SPMTs. There, they were positioned on a specially designed barge that could land on the beach near the site as there was no dock facility available. The modules were driven off via an installed ramp and temporary road over the beach to the storage area then transported to the site for installation. The gantry lifted the modules from the SPMTs to the right level. from there, they were skidded into the evaporator unit for installation. ■

SOMETIMES THE SAFEST SOLUTION IS ALSO THE FASTEST

Proven engineered heavy lifting and transport expertise ensures that

safety remains paramount while opportunities for efficiency are realized.

HELPING TO CONSTRUCT

THE FUTURE OF NUCLEAR

POWERCONSTRUCTION



Since the design of the first fully commercial nuclear reactors in the late 1950s and 1960s nuclear energy has been part of the global

power supply. While there was not much growth in the industry during the 1980s, the share of nuclear in the mix of world power supply remained fairly constant, as capacity slowly grew and output steadily increased. By the late 1990s, commissioning of newer reactor designs, known as third-generation reactors, began in response to the increased demand for energy across the globe.Plant construction has changed over the years, with some companies choosing to use standard designs for plants and their compo-nents and a ‘modular’ approach to their assembly. Constructing and pre-assembling pipework and other elements of the plant off-site and then shipping these pre-assemblies to the facility site has many advantages. This approach can reduce risks, keep the project schedule on track and enable work to be carried out where specialized skills are availa-

ble. However, it requires specialized transport and installation services.For large pre-assembled plant structures and heavy, outsized components that need to be transported safely and with extreme care, it is essential to have the right team and equip-ment to carry out the job. Development of new transport methods and lifting technology can unlock innovative plant design. By free-ing up plant and component designers and engineers to exploit different techniques in plant design and construction, the industry has the potential to drive forward more safety improvements and avoid construction delays.

OPTIMIZATION OF THE WHOLE

Constructing nuclear plants is complex, with multiple activities simultaneously performed by diverse contractors and subcontractors. Each contractor works according to their own scope of tasks and schedule, deploying their own equipment and employing the peo-ple to operate it. However, their individual

efforts are generally not aimed at overall pro-ject efficiency and optimum utilization of resources. For both civil plant construction and delivery of major components there are advantages to the critical path from stream-lining of processes.

DEDICATED SPECIALISTS

The mix of contractors and complex division of responsibilities can lead to situations where communication becomes less effec-tive, unnecessary amounts of equipment are on site, delays cannot be avoided and, ulti-mately, safety is compromised. By concen-trating similar activities with specialized suppliers, these complications can be miti-gated. This is where one dedicated company can cover all heavy lifting and transport activi-ties in one optimized package. This serves the overall objective of the entire project: to bring the plant online safely and cost effec-tively. It also makes the construction process more manageable for the plant owner and operator. ■


EXPERT INSIGHT

Pete Ashton is the Nuclear Services Director for Mammoet USA. Pete has been involved with specialized rigging systems and cranes for large component handling related to maintenance and replacement outages, decommissioning and new construction since 1999. Here he provides a viewpoint on how Mammoet helps facilitate optimization of nuclear plant construction:

Optimization of engineered heavy lifting and transport when building a new plant, for both the civil construction and

component installation, is still uncharted territory in many nuclear projects. It offers great opportu-nities to cut risks, improve safety, avoid delays and streamline processes. Mammoet helps clients identify efficiency improvements, both on-site and in the construction processes, thereby avoiding costly over-runs.

We can also improve the quality of the con-struction process through the application of site-wide standards and seamless communication and handover at each stage of the project.

Looking to the future, increased modulariza-tion of construction and standardization of com-ponents or plant design has an important role to play in nuclear plant construction optimization. Here Mammoet has a vital role to play in provid-ing creative route, engineering and equipment solutions tailored to the project’s specific needs. The construction process can fully exploit a modular approach when innovative transport and lifting solutions are provided.

But whether new plant owners choose to use offsite pre-assembly of large structures prior to installation, fully modular construction or a stick-build approach, when lifting & trans-port is carried out by one party, efficiency gains can be achieved. This minimizes the safety and process risks associated with multiple contrac-tors and maximizes the efficiency of the trans-port and construction processes. In short, single sourced lifting and transport activities contribute to increased safety and optimized schedules. ■

OPTIMIZING NUCLEAR PLANT CONSTRUCTION

SINGLE SOURCED ENGINEERED HEAVY LIFTING AND TRANSPORT SERVICES

Working in close partnership with the site owner, a single engineered heavy lifting and transport contractor can assess priorities, equipment require-ments and risk management plans. This has many advantages: One pool of equipment and

professionals is responsible for the safe execution of all lifting and transport activities on site.

Communication is simplified. Fewer operators are on site and labor

costs are reduced. Standardization of job preparation

and execution leads to increased safety and efficiency.

Less equipment on site keeps the site clearer and is more efficient plus it reduces costs associated with mobilization and demobilization.

“ Mammoet optimized the installation processes to ensure they were carried out as swiftly and safely as possible. As a result on-site disruption was minimized.”OLIVIER FRELAND, NEW CONSTRUCTION DEPARTMENT HEAD, AREVA


FOLLOWING A SMOOTH CURVE TO INSTALLATION

During the construction of the first Generation III+ EPR™ reactor at the Olki-

luoto 3 site in Finland more than 4,000 people from 55 different countries were working at the site. This made it one of the largest industrial projects ever carried out in Northern Europe.Mammoet was contracted to pro-vide heavy lifting capacity for the reactor building civil works and also deliver and install the major nuclear components, including the Reactor Pressure Vessel (RPV), four steam generators and a Reac-tor Closure Head (RCH). Construction on the plant began in february 2005, Mammoet provided a PTC-35 on site to carry out the lifting work for the construction of the main reactor and turbine build-ings and other auxiliary building works. The PTC provides lifting capacity up to 1,600 metric tons making it suitable to lift the reactor building’s heavy prefabricated steel liners into place. Due to its lifting speed and flexibility it was also able to carry out other lifting work, including smaller loads, reducing the need for multiple cranes. In January 2009 the RPV arrived on site from Japan, the RCH had arrived from France and in autumn 2009 the plant’s dome, designed to withstand an aircraft crash, was

installed on the reactor building and the steam generators arrived on site. In June 2010 component installation began. Installation of heavy components of the primary cooling system was complete by November 2011. The plant’s design created some interesting puzzles for the Mam-moet engineers to solve. It was necessary to enter the reactor building through the equipment hatch. This hatch was only acces-sible via the fuel building. This cre-ated two challenges for the installation process. Firstly the entrance to the fuel building was 19 meters higher than ground level. Secondly the equipment hatch was not accessible in a straight line from the fuel building entrance. To tackle these two obstacles a gantry and support structure were designed to raise the components from their trailers to the height of the fuel building entrance. From there the components were maneuvered into the reactor build-ing on a skid system. As the route was not straight our usual linear skid system could not be used. Once again our engineers set to work on a tailor-made solution to the dilemma, creating a curved skid track to deliver the compo-nents safely into their new home. ■

OLKILUOTO 3 • FINLAND CASESTUDY


“ In Finland we were very impressed with Mammoet’s precise and detailed approach to the project at every stage. The extensive planning and preparation paid off. All the components in their care were safely delivered and installed exactly when we requested it. This was despite a changing schedule. The flexibility demonstrated by Mammoet, following changes to installation dates, was a huge help during the project’s construction phase.”OLIVIER FRELAND, NEW CONSTRUCTION DEPARTMENT HEAD, AREVA


CHERNOBYL • UKRAINE

Shortly after the Chernobyl Nuclear Power Plant accident in 1986, an emergency shelter was placed over

the destroyed reactor. Built with great haste at the time, this structure would eventually have to be replaced by a more permanent solution.Mammoet was asked to aid in the construc-tion and installation of the new arch-shaped

safe confinement. It was Mammoet’s task to engineer a plan to lift, skid and install the 36,200-ton shelter from its clean and safe construction site to its destination for the next hundred years.The arch-shaped confinement was built in two halves by contractor Novarka. At 165 meters long, 260 meters wide and 110 meters tall, it required a unique approach

and specialized equipment to ensure both the capacity to deal with such size and weight and the accuracy to deliver it with millimeter precision. Mammoet developed a lifting system and software to control 56 strand jacks simultaneously and a skidding system consisting of 116 skid shoes with a capacity of 700 tons each. Each half of the arch was lifted in three stages, allowing the crew to work at lower heights, increasing cost-efficiency and oper-ational safety. Once the first half was raised, it was skidded out of the construction area to make room for assembling the second half. Upon completion of the second section, the first was skidded back to enable the connec-tion of both halves.In 2016 Mammoet skidded the complete 36,200-ton arch from the construction area, over a distance of 330 meters, into place over the reactor building. Mammoet’s approach had many advantages – only half the jacking capacity was needed compared to raising the arch in one piece, greatly reducing costs. Cost-efficiency and safety were further increased because each half was elevated in three jacking operations. Last, but not least, Mammoet’s remotely operated equipment prevented the crew from having to work in the contaminated area, making this project a text-book example of safe, cost-efficient and out-of-the-box engineering. ■

BUILDING AN ARCH TO STAND THE TEST OF TIME

Skidding arch 1 from the special erection area (A) to the waiting area (B) using a custom-built skid system. The second arch is erected using the same method as the first arch.Arch 1 is skidded back to join arch 2. The complete arch is skidded into place over the damaged reactor building (C).

A Special erection area: dedicated area for construc-tion activities.

B Waiting area: temporary location for arch 1.

C Reactor Unit 4: area to be confined.

SITE OVERVIEW

CASESTUDY

ARCH 2ARCH 1



Each nuclear plant has its own challenges when vital components need to be renewed or upgraded. Detailed coordination, teamwork and a sharp focus on safety are necessary to ensure these operations are smoothly executed and limit expensive downtime.

INNOVATIVE APPROACHES

TO SAFELY CUT DOWNTIME

OUTAGES


Many plants were not designed with shutdown activities in mind. Adding to shutdown complexity is the fact that

multiple parties are generally working simultaneously at the same site. These realities call for a comprehensive approach that takes into account not only the movement of the different components, but also the safe coordination of activities carried out by different subcontractors.

LIFTING AND TRANSPORT

Each nuclear plant was customized according to the technology and insight at the time of their construction. In many cases, their infrastructure does not allow for easy and swift change-out of large key

components such as steam generators and reactor vessels. With many plants operating for 30–40 years, there is an ongoing program of component renewal and replacement. As downtime is very costly, innovative approaches to the lifting and transport of components are needed to ensure outages are executed as efficiently as possible. Current lifting & transport technology offers new possibilities for turnaround projects, particularly those not designed with efficient turnaround in mind.

MECHANICS AND LOGISTICS

Plant owners are often unaware of this when they start working on the mechanical engineering for maintenance projects. It

“ I would like to convey my great and very sincere congratulations for the successful lifting operation of the first steam generator. Once again, you have shown a professional attitude which is a model of quality, method and reliability.”JP MOUROUX AREVA NP, CFS PROJECT DIRECTOR OL3


The mechanical engineering plan should be integrated with a detailed logistics plan.

EXPERT INSIGHT

Michel Bunnik is Mammoet’s Sales Director for the Middle East. Since 2000, he has been involved in most of the nuclear construction, outage and decommissioning projects that Mammoet has executed. Here he explains our specialized approach to nuclear outages.

Mammoet can offer possibilities and smart approaches that help deliver more efficient

turnarounds; providing solutions to facility-specific issues regarding difficult-to- reach locations, confined spaces and transportability in general. Our engineers have developed a unique outage concept that is based on the detailed pre engineering of all heavy lifting and transport work. The Mammoet concept also optimizes the planning and coordination of different maintenance activities performed by different parties on site.

This results in greater cost-effectiveness, as the overall operation becomes more streamlined and equipment is better utilized. Our detailed approach has a positive and significant effect on total downtime in shutdown projects and the associated costs thereof. For many Mammoet customers, this approach has become the preferred standard for shutdown management – it is now even used in some other industries.

Current heavy lifting and transport technology offers many opportunities to minimize downtime in safe ways that were not foreseen at the time of the plant’s construction. As demonstrated by the Davis-Besse project, an integrated approach offers significant benefits: it optimizes processes and can complete outages faster while maintaining the highest safety standards. ■

UNIQUE OUTAGE CONCEPT

makes a significant difference in the efficiency of these projects when engineered heavy lifting and transport activities are integrated from the beginning. They define the critical path of a maintenance operation and therefore the actual downtime. The timing depends on many factors, particularly the internal layout and installations that define the room to maneuver, the capacity to lift and potential complications along the way. Therefore, the mechanical engineering plan should be integrated with a detailed logistics plan to encompass all lifting, transport and change-out of the large key components involved. ■


In 1978, the Davis-Besse Nuclear Power Plant was the 50th nuclear power plant to come online in the USA. In 2009 it was

decided that the Reactor Vessel Closure Head (RVCH) and the two steam generators had to be replaced. The replacement was set for 2014, and at that time there were known complications. First, the polar crane in the plant was not strong enough to lift an entire steam generator for replacement. Second, the floor level inside the Davis-Besse nuclear power plant is around six meters higher than ground level outside.Usually, replacement projects in nuclear power plants are performed by creating a temporary hatch in the plant’s wall, big enough to skid the old steam generators out and the new ones in before they are installed. However, the floor level height inside the plant made it necessary to create a temporary hatch six meters above the outside ground. This would require Mam-moet to lift the steam generators, however the presence of power lines delivering elec-tricity to the grid ruled out the use of cranes to simply lift the steam generators in and out of the plant. Mammoet proposed pushing the components up from below positioning them at the correct height to move them through the temporary hatch using the JS500 jack-up system. Inside the plant Mammoet installed a temporary lifting device consisting of a 900-ton strand jack on a travelling gantry system that provided the additional lifting capacity needed for the entire operation.

DEALING WITH THE UNFORESEEN

An inspection by the Nuclear Regulatory Commission in 2010 ruled that the RVCH at Davis Besse had to be replaced sooner than anticipated, during a midcycle outage in the fall of 2011. This meant the deadline was moved forward by three years and the work had to be divided into two parts: replacing the RVCH in 2011, and then replacing the two steam generators in 2014.

REPLACING THE RVCH

By working around the clock, the technical crew managed to meet the new deadline and complete the test-loading and fit-testing by the summer of 2011. Mammoet replaced the 140-ton RVCH during the planned outage,

DAVIS-BESSEUSA

IN AND OUT THE HATCH

safely and smoothly, three years ahead of our original deadline. Immediately after the RVCH replacement preparations began for the removal of the two steam generators. Everything was pre-assembled and in posi-tion by January 2014 but then bad weather hit the project.

AGAINST THE ELEMENTS

When the replacement operation officially got underway in February 2014, the region was being ravaged by the worst winter in 30 years. This caused all kinds of problems for the team, who worked in two rotating shifts of twelve hours, six days a week for ten weeks with three meters of snow on the ground and temperatures between -10°C and -40°C. The machines were covered in

thermal blankets and kept idling at all times so that the engines wouldn’t freeze. Special industrial heaters were also mounted on the power packs against the severe cold.

STEAM GENERATOR EXTRACTION

Once the plant had cooled down, a tempo-rary hatch was made in the plant’s concrete wall. This large entrance allowed us to move all our equipment and transport the steam generators in and out. The JS500 was arranged in front of the work platform and a connecting skid way on top of it provided the route inside the plant that the generators would travel – both ways. Once each steam generator was skidded out of the plant, it was quickly transferred to its final resting place in the mausoleum, a concrete bunker

CASESTUDY


DOEL • BELGIUM

In 2004, two steam generators at the Doel Nuclear Power Station needed to be replaced. Mammoet was asked for a solution that would keep plant outage to a minimum. The

conventional solutions of skidding the steam generators through the side of the reactor building would take too much time. Instead, Mammoet proposed to exchange them through the roof. A safe alternative approach that got the job done faster than the conventional way.In the 1990s Mammoet replaced the steam generators for Doel 3 and 4. Back then, we used the conventional method of skidding the steam generators through the side of the building. The downside of this procedure is the large amount of time lost while removing components to create space inside the reactor building to move the steam generators in and out. With this in mind the Mammoet engineers started working on alternatives. Fortunately, a lot had changed since then. Because of technological advancements, our crane fleet had reached record heights of lifting capacity. Instead of having to go in from the side, we could now come in from above. As a result, there was no more need to disassemble components inside the plant other than the steam generators themselves. We had already won time before we had even begun. Before the old steam generators could be replaced with the new ones, a number of panels had to first be removed from the roof of the reactor building.The old steam generators were then extracted with a 1,600-ton PTC-35 ring crane and tailed in a horizontal position with a 500-ton hydraulic crane. Once the old steam generators were placed on stools in the storage building, we transported the new units from the temporary storage area and lifted the two new 313-ton steam generators into place through the openings in the dome. Fast, safe and efficient. Through this innovative approach, outage time was reduced by 10 days (30%). Less time in and around the plant meant less exposure time for the crew involved, no insignificant fact in a field where safety comes before everything else. Five years later, this same client asked us to replace the steam generators for Doel 1 following the same procedure. The entire plant was now up to date again for years to come. ■

INNOVATIVE EQUIPMENT UNLOCKS TIMESAVING METHOD FOR REACTOR REPLACEMENT

CASESTUDY

with walls so thick that no residual radiation can escape. Then the whole process was repeated for the second steam generator. The new steam generators were installed using the same procedure, but in reverse.

A TOUGH JOB, WELL DONE

The first steam generator was extracted on 28 February 2014 and the last new steam generator was set on its foundation on 11 March 2014. It was the first time that the pro-cedure had ever been carried out and it was specifically developed for this project. Our plan enabled us to work quickly; every day saved meant saving a million dollars for our client. We beat the revised deadline for replacement of the RVCH and delivered everything without incident. ■

The components were raised six meters above ground level on a jack-up system.


Safety and high quality execution are just as necessary at the end of a nuclear facility’s lifespan as during its construction and operation. Especially since these facilities are not generally designed with efficient decommissioning in mind.

JOURNEY’S ENDSAFE

AND SECUREDECOMMISSIONING


The places where facilities have been constructed – whether by the coast, in a desert, or an urban area – are pivotal in

defining the safest and most sustainable decommissioning method. Once decom-missioned, the various parts must be removed and transported to their final destinations.Expertise and creativity from the engi-neered heavy lifting and transport sector can be used to identify opportunities for safer and more efficient decommissioning of nuclear plants. The experience of con-structing and upgrading these plants cre-ates a knowledge base from which those processes can be ‘reverse engineered’ to deliver a safe and streamlined decommis-sioning process. ■

“ Mammoet have brought their extensive international experience to site and both ourselves and our client agree the site is far better for this. Mammoet have been a success story for Hertel.”DES GRAVES DECOMMISSIONING MANAGER HERTEL

EXPERT INSIGHT

Sales Director for the UK, Darren Watson, has been with Mammoet since 2009, providing commercial support to nuclear projects within the UK. Darren works with an experienced project sales team who have been involved in many nuclear projects including the Evaporator D module installation, decommissioning of the world’s first nuclear power station (Calder Hall) and the topping and tailing of a 100 ton stack removal at Sellafield as part of the ongoing SDP works.

In the past decades, Mammoet has been involved in both the construction and decommissioning of virtually every type

of installation. Every decommissioning pro-ject is unique and they often call for innova-tive, tailor-made solutions. As in all our activities, decommissioning projects start with a detailed plan in which we have engi-neered the best technical approach, the planning as well as all safety aspects of the project.

Our experience in nuclear plant construc-tion and maintenance enables us to provide specialist insight re-enforced by years of experience within decommissioning. We also have the equipment to do the job. The fleet can perform the necessary activities for each decommissioning project using, for example, cranes and other lifting devices such as gantries and pushup systems. All are put to use to safely detach and remove the parts of installations.

Mammoet’s equipment and the expertise of our professionals form a unique combina-tion for decommissioning. It is this combina-tion that enables Mammoet to provide solutions for any decommissioning situation, and then successfully deliver them – ensur-ing safety, costeffectiveness and as little environmental impact as possible. ■

TAILOR MADE SOLUTIONS FOR EACH NUCLEAR DECOMMISSIONING PROJECT


NUCLEAR DECOMMISSIONING THROUGH A BOTTLENECK

In the French Ardennes, the Chooz A nuclear plant was scheduled for decom-missioning. Mammoet France was con-

tracted to remove the plant’s heavy components, but the Chooz A offered a special challenge: it was located inside a mountain.A unique design feature among nuclear plants, the mountain location required solu-tions that allowed work in a very limited space. Mammoet responded by designing and building a range of tailor-made equip-ment for the job. The highlight of the project was the removal of four 120-ton steam gen-erators through a narrow angled corridor. With a hydraulic rotating mechanism, Mammoet successfully removed the steam generators from their foundation positions – sometimes moving them through openings

with less than 100 millimeters to spare. With the Chooz A plant literally inside the mountain, there was no way to extract the 120-ton units in a straight line through the roof or walls, and stringent nuclear safety regulations ruled out most scenarios for removal of the steam generators. With mini-mal exposure to contamination time in mind, Mammoet devised a solution that could safely and in the shortest possible interval get the units through the cornered corridor and out of the containment area. Mammoet came up with an approach and designed the tools needed for the job. Leading the innovations was a rotating mechanism powered by four hydraulic jacks. This ground-breaking device was capable of tilting the steam generators pro-gressively during lifting as they were moved

forward with the overhead gantry crane. Using trolleys adapted for the existing rail system, the steam generators were safely moved into a decontamination area, and afterwards removed by SPMTs.Mammoet was able to swiftly extract the steam generators from a seemingly impos-sible position by conducting thorough research and applying its extensive engi-neering expertise. Since successfully wrap-ping up the Chooz A project, Mammoet has since been contracted to handle other steam generator removals all over Europe. Innovations like the system created for the Chooz A reactor have been put to use in many of these projects. And should circum-stances require a different solution, Mam-moet creates the tools and strategies to do the job efficiently and safely. ■

CHOOZ A • FRANCECASESTUDY


JÜLICH GERMANY

MAMMOET HANDLES A 2,000 TON PROTOTYPE NUCLEAR REACTOR

Mammoet worked on the design and execution of a project to extract a

reactor vessel from a nuclear pilot reactor in Jülich, Germany. The removal of the reactor vessel was a highly complex operation, requiring the highest safety and environmental protection measures to be in place. The reactor was a prototype pebble bed reactor which was constructed in the 1960’s. Its purpose was to demonstrate the feasibility and viability of a gas-cooled, graphite-moderated high temperature reactor. It was shut down in 1988 after 20 years of operation. Before decommissioning could begin, a large building known as a material lock, was constructed over the existing reactor building. This allowed the reactor building to be opened in a protected environment for removal of the reactor vessel. Mammoet custom designed the skidding and lifting equipment to move the reactor vessel from the reactor building into the material lock. The vessel weighs 2,000 tons, is 26 meters high and has a diameter of 7.6 meters. It was lifted from its former position in the reactor building, moved and then placed into a custom-built support frame. The reactor vessel was lifted out of its support frame and moved from a vertical position into a horizontal position. It was then placed in a transport frame, and transported on Self Propelled Modular trailers (SPMT) to a purpose built storage building where it will rest for the next 40–60 years until final storage is available in Germany. ■

CASESTUDY



A distinguished safety track record, nuclear industry-specific expertise, innovative

engineering solutions and an extensive fleet of reliable and high quality equipment are essential

to guarantee the levels of safety, quality and reliability necessary for nuclear projects.

CREATIVEENGINEERING,

CAREFULPLANNING AND

SAFE DELIVERY

PROFILE


We believe our business is about time: uptime, turna-round time and time to mar-ket. To our customers, time is

the currency that matters most. That’s why we strive to bring their deadlines forward. It’s an integrated, daily effort shared by everyone at Mammoet, in every aspect of our services: creative engineering, careful planning and safe delivery. Over two hundred years of operational experience, from jobs in a wide variety of circumstances, ensures that Mam-moet can come up with effective approaches for challenging situations. Our services are focused on the petrochemical and mining industries, civil engineering, power genera-tion and offshore projects. The logistic chal-lenges in these industries are growing daily. Factors such as remote locations, harsh cli-mates and a strong emphasis on the environ-ment are constantly driving us towards smarter and safer solutions.

Mammoet’s services in Engineered Heavy Lifting and Transport comprise: Heavy lifting services Heavy transport services Plant turnaround / shutdown management Site-wide construction services Modular construction Factory-to-foundation / logistics Emergency response & wreck removal Decommissioning of onshore and offshore

Installations Trading in new and used equipment

worldwide

We have the largest and most modern fleet of equipment available in the world. The unique capability of our equipment, com-bined with our experience, enables us to get the best results from our services and unlock more efficient ways of working. Strict mainte-nance programs ensure maximum safety and reliability. After all, when our customers

“ I want to thank Mammoet in his globality for the great job done on site, for his pro-activity and his patience. If you had any doubt about it, I confirm that it’s a pleasure to work with you. I hope that the great job done by Mammoet for Tihange will continue for Doel.”FABRICE COLLAVINO, ADJOINT SERVICE MAINTENANCE SPÉCIALISÉE – IBRM-F, AREVA NP


We have a track record in nuclear projects going back over forty years. This, combined with our specialized fleet of equipment and well trained

professionals, can deliver significant improvements in safety, efficiency and cost-effectiveness for the industry. We have the largest fleet of heavy lifting and transporting equipment in the world, including technology developed specifically for the nuclear sector. This equipment and our expertise in operating and developing it, is what reduces construction times and brings forward commissioning dates for our clients.

At Mammoet, safe delivery, is paramount. Over many years, Mammoet has built a safety track record that stands out in the industry. Wherever we operate in the world, our employees work to the highest level of safety standards to ensure a flawless execution. Our manage-ment takes a prominent role as the driver of positive safety behavior with employees working according to thoroughly evaluated systems and processes. This places safety at the center of our focus, making it an integral part of how we evaluate performance. Like safety, sustainability is another key element in how we evaluate performance. We support our client’s efforts to protect the environment with innovative engineering solutions and in-depth under-standing of the possibilities of our equipment. The highest safety and quality levels are guaranteed by the global standards and procedures we have adopted. Our large and well-maintained fleet of equipment is subject to strict maintenance schedules, which always meet, but often exceed, the manufacturers’ protocols. Our extensive fleet of equipment is only one part of the package, it is our pro-fessionals who bring another level of quality to our ser-vices. Well-trained staff with extensive experience from practical situations bring strict project discipline, insight and problem-solving to our operational work. This unpar-alleled level of quality execution in nuclear projects is why the industry consistently turns to Mammoet to deliver their engineered heavy lifting and transport needs. ■

QUALITY AND RELIABILITY COME AS STANDARD

EXPERT INSIGHT

Herman Smit, Advisor to Mammoet’s Board, has been managing projects and providing expertise in various directorial roles at Mammoet since 1981. He describes how clients can rest assured that their plant is in the right hands when they work with Mammoet.

choose Mammoet, we want them to be sure of one thing: that Mammoet professionals and their equipment get the job done well, safely and on time.

QUALITY ON A GLOBAL SCALE

Mammoet has operations in each of the major regions of the world; it is this vast cov-erage that allows us to mobilize and synchro-nize each region’s resources to suit our customer’s needs. The biggest projects we operate in usually involve the transport of large technical units from one side of the globe to the other. All our work is carried out according to ISO 9001.All procedures, checklists and instructions comply with this standard. This system ensures that all equipment and services sup-plied to our customers are in accordance with the standards and specifications of the relevant contract, in conjunction with all applicable regulatory requirements. ■

For the Chernobyl New Safe Confinement project Mammoet developed a software-controlled lifting system which simultaneously operated 56 strand jacks.


BABCOCK MARINE • UK

Babcock Marine was looking for a way to remove a 1,450-ton, 125-meter-long, refueling crane from their

Devonport dockyard. Built in the 70’s to replace fuel rods in nuclear submarines, a new gantry system had made the crane obsolete. Instead of taking the crane apart piece by piece, Mammoet suggested remov-ing it whole and demolishing it elsewhere; a solution that saved thousands of man-hours and kept the yard open for business.Babcock Marine had been told that demolish-ing the old hammerhead crane on site was the

only way to get rid of it. However that approach would have meant slowly deconstructing the crane, requiring a significant amount of hours working at dangerous heights. In addition, the offices beneath the crane would need to be vacated for months on end.Mammoet proposed removing the crane in one piece, solving both problems at once. Over 2,000 tons of equipment were needed for the job, including gantry beams, skid shoes, strand jacks and four mobile cranes. Mammoet jacked up the 1,450-ton crane and skidded it across the beams.

Using strand jacks, the crane was then low-ered onto a barge 40 meters below. From there, the largest dockside crane in Western Europe was tugged to its final disassembly location. Within twenty hours, the crane was taken down. The operation reduced the total downtime for the dock and enabled the nearby offices to continue in operation, sim-ply evacuating for short periods during crane lifts over the buildings, avoiding the need for long-term relocation of several hundred workers. ■

MINIMIZING DISRUPTION BY THINKING BIG

CASESTUDY


KURSK SUBMARINERUSSIA

On August 12, 2000, a devastating explo-sion sank the Russian nuclear submarine Kursk in the Barents Sea. The Kursk hit the

seabed 108 meters below, driving its bow 2 meters deep into the clay. Mammoet was awarded the sal-vaging contract in May, 2001 and within a 3-month period, over 3,000 tons of tailor-made equipment was designed, fabricated, installed and commis-sioned onto a barge which was mobilized to the Barents Sea in August.The wreck of the Kursk had to be raised before the winter weather made salvaging impossible. The submarine’s bow was stuck so deep in the seabed,

CREATIVE ENGINEERING AT THE BOTTOM OF THE SEA

the biggest concern was that the heavily damaged bow might break off and destabilize the lifting process. Apart from the delays a break-up would cause, it would also be extremely dangerous. The Kursk still contained a number of unexploded torpedoes and 24 cruise missiles – not to mention two nuclear propulsion reactors. To safely raise the sub, Mammoet conceived a daring plan to first cut off the bow at the bottom of the sea. Using a tailor made cutting wire that was hydraulically pulled back and forth between two suction anchors, the bow was sawed off in 10 days.With the Kursk now free for lifting, 26 holes were cut in the hull to accommodate special lifting plugs. Each plug was connected to a set of strands that were gripped by a strand jack on deck of the barge above. On October 8, 2001, the Kursk was pulled free from the seabed and towed to Murmansk. Fourteen months after that disastrous August morning, the Kursk, and the bodies of 115 sailors tragically killed, were finally home again. ■

CASESTUDY

Over many years, Mammoet has built a track record that stands out in the industry.


Exelon Corporation Byron, USA. Byron GS Transformer Transport. Byron Outage One and Two. Scheduled Feb 2017 to May 2019Exelon Business Services York, USA. Generator Rotor PBAPS. On site relocation of one old generator rotor and one new generator rotor at Peach Bottom Atomic Power Station (PBAPS). Scheduled 2017Siemens Industrial Turbomachin-ery AB Ringhals, Sweden. Ringhals 1 Roger and TREX. Replacement of 380 tons generator in BWR using a custom gantry system and strand-jacks. Replacement of 2x trafo. Completed May 2016ABB Power Doel, Belgium. Trafo Exchange 2x 147t Completed 2016Areva NP SAS Flamanville, France. Inst. EPR Nuclear Components Trans-port, lifting and installation of 10 pri-mary components in new nuclear power plant. Completed 2016NA-SA Embalse. Exchange of 4 x steam generator lower assemblies. Embalse ARG. Completed 2015Areva NP France Doel. Exchange of reactor head. Doel, Belgium. Completed 2015Areva NP France Tihange. Exchange of reactor head. Tihange, Belgium. Completed 2015Nuclear Waste Management Oakville, Canada. NWMO-OPG DSC Offload. Offload, skid and set Dry Storage Container. Completed 2014Dansk Decommissioning Riso, Denmark. TSP / TSR removal and transportation. Removal of the TSP and TSR of 10MW nuclear reactor DR3 in Riso, Denmark. Transport to final storage. Completed 2014Bechtel Davis Besse Unit 1. Exchange of 2 x 550-ton steam generators. Oak Harbor, USA. Scheduled 2014Carolina Energy Services Bruns-wick. Exchange 4 x 25- ton MSR bun-dles. Southport, USA. Scheduled 2014WSI Aquilex Angra 2. Echange of 1x 70-ton reactor vessel closure head. Angra, Brasil. Completed 2013–1 to 2013–3Areva NP France EDF Flamanville 3. Installation of 410-ton reactor pressure vessel, 4 x 550-ton steam generator, & 110-ton pressurizer with outside lifting gantry, high level skidtrack and 2 temporary lifting devices on top of polar crane. Flaman-ville, France. Completed 2014–6SGT– Steam Generating Team, TVA Sequoyah Unit 2. Exchange of 2 x 380-ton steam generators with 2,000- ton capacity crane, PTC. Soddy Daisy, USA. Scheduled 2012EDF Chinon. Decommissioning, lifting and transportation of heat exchangers from reactor building to storage facility. Chinon, France. Scheduled 2012SGT– Steam Generating Team, Entergy Waterford. Exchange of 2 x 650-ton steam generator and 1 x 150- ton reactor vessel head. Hahnville, USA. Scheduled 2012AVR-Julich Julich Decommission-ing. Removal of 2,200- ton old reactor pressure vessel from reactor building in 1 piece with gantry system. Julich, Germany. Scheduled 2012Bechtel Davis Besse Unit 1. Exchange of 1 x 180-ton reactor vessel closure head. Oak Harbor, USA. Completed 2011–10Areva NP France Taishan. Installa-tion of 410-ton reactor pressure vessel, 4 x 550-ton steam generator, & 110-ton pressurizer with outside lifting gantry, high level skidtrack and 2 temporary lifting devices on top of polar crane. Taishan, China. Completed 2011–9 to 2013–6Areva NP France Ringhals 4. Exchange of 2 x 320-ton steam generator and 1 x 120- ton pressurizer with TLD inside and 800-ton crawler crane outside. Ringhals, Sweden. Completed 2011–5

EDF Chooz A. Decommissioning, lifting and transportation of old steam generators from reactor building to storage facility. Chooz, France. Completed 2011–02 Exelon USA Fleetwide. Long term agreement for fleet wide transformer exchange up to 35 units over 300 tons. This includes emergency transformer replacement. USA. Completed 2010–2012Exelon Desden 3 Nuclear Station. Exchange of feedwater heater. Morris, IL, USA. Completed 2010–11Framatome France Olkiluoto 3. Installation of 410- ton reactor pressure vessel, 4 x 550-ton steam generators, & 110-ton pressurizer with outside lifting gantry, high level skidtrack and 2 temporary lifting devices on top of polar crane. Olkiluoto, Finland. Completed 2010–06 to 2011–03Westinghouse Doel 1. Exchange of 2 x 360-ton steam generator through roof of reactor building with 1350- ton crane. Doel, Belgium. Completed 2009–12SGT– Steam Generating Team, Exelon Three Miles Island. Exchange of 2 x 550- ton steam generator. Middletown, USA. Completed 2009–11

Progress Energy Florida Crystal River 3. Exchange of 2 x 550-ton steam generator. Florida, USA. Completed 2009–11Babcock & Wilcox Crystal River 3. Inland Transport & Delivery of 2 x 550-ton steam generator. Florida, USA. Completed 2009–10Carolina Energy Services Cooper Nuclear Station. Exchange 4 x 45-ton feedwater heaters. Brownville, USA Completed 2009–09SGT– Steam Generating Team, PG & E Diablo Canyon 2. Exchange of 4 x 360-ton steam generator with outside lifting gantry, skidtrack and temporary lifting device inside the reactor building. California, USA. Completed 2009–05 Iberdrola Angra 2. Exchange 2 x 380-ton steam generators. Angra, Brasil. Completed 2009–03 Carolina Energy Services Cooper Nuclear Station. Exchange 2 x 40-ton feedwater heaters. Brownville, USA. Completed 2008–04SGT– Steam Generating Team, PG & E Diablo Canyon 1. Exchange of 4 x 360-ton steam generator with outside lifting gantry, skidtrack and temporary lifting device inside the reactor building. California, USA. Completed 2008–02 SGT– Steam Generating Team, Exelon & PSEG Salem 2. Exchange of 4 x 360-ton steam generator with outside lifting gantry, skidtrack and temporary lifting device inside the reactor building. New Jersey, USA. Completed 2008–02SGT– Steam Generating Team, FPL St. Lucie Nuclear Powerstation 2. Exchange of 2 x 550-ton steam generator, 140-ton reactor head and 100-ton pressurizer with tailor made lifting equipment. Florida, USA. Completed 2007–11SNC Lavallin Bruce. Exchange of 2 x 8 steam generators for both power units. Exchange with 1600- ton PTC ring crane through roof. Ontario, Canada. Completed 2007Rigging International Watts Bar. Exchange of 2 x 360-ton steam generator through roof of reactor building with 1600- ton PTC ring crane. Springville, Tennesse, USA. Completed 2006–12Weldtech Cooper Nuclear Station. Exchange 2 x 40-ton feedwater heaters. Brownville, USA. Completed 2006–10Energie Werke Nord Lubmin / Greifswald 1 to 4. Decommissioning, lifting with gantry, skidding and transportation of 2 x 400-ton and 2 x 650-ton reactor pressure vessels. Lubmin, Germany. Completed Phase 1 – 2007, Phase 2 – 2009Taiwan Power Company Lungmen 2. Installation of 950-ton reactor pressure vessel into reactor building with MSG 50 crane. Lifting radius 65 meters. Lungmen, Taiwan. Scheduled 2006–10SGT– Steam Generating Team, Entergy ANO 1. Exchange of 2 x 520-ton steam generators & 180-ton reactor head. Russellville, Arkansas. Completed 2005–11SGT– Steam Generating Team, Ameren Callaway. Exchange of 4 x 340-ton steam generators with CC2800 crane and strand jacks. Callaway, USA. Completed 2005–10SGT– Steam Generating Team, FPL St. Lucie Nuclear Powerstation 1. Exchange of 140-ton reactor head and 100-ton pressurizer with tailor made lifting equipment. Florida, USA. Completed 2005–10Babcock & Wilcox Fort Calhoun. Transport/delivery of 2 steam generators, reactor head and pressurizer. Nebraska, USA Completed 2005–06SGT– Steam Generating Team, FPL Turkey Point 4. Exchange of 100-ton reactor head with tailor made lifting

gantry and tailing frame. Turkey Point, USA. Completed 2005–03Taiwan Power Company Lungmen 1. Installation of 950-ton reactor pressure vessel into reactor building with MSG 50 crane. Lifting radius 65 meters. Lungmen, Taiwan. Completed 2005–03Framatome Germany Olkiluoto 3. Rental of 1600- ton capacity PTC ring crane for new construction of nuclear power plant, type EPR. Olkiluoto, Finland. Completed 2005–02SGT– Steam Generating Team, Xcel Energy Prairie Island 1. Exchange of 2 steam generators with CC2600 crane, mast system and strand jacks. Steam generators exchanged in 2 parts, 200 & 150 tons. Prairie Island, USA. Completed 2004–12SGT– Steam Generating Team, FPL Turkey Point 3. Exchange of 100-ton reactor head with tailor made lifting gantry and tailing frame. Turkey Point, USA. Completed 2004–10SGT– Steam Generating Team, Duke Energy Oconee 3. Exchange of 2 x 550-ton steam generators using gantries and 15 meter high skidtrack. Oconee, USA. Completed 2004–10Babcock & Wilcox Oconee. Transport/delivery of 2 steam generators and reactor head. Oconee, USA Completed 2004–04Westinghouse Energy Systems Europe S.A. Doel 2. Exchange of 2 x 360-ton steam generators through roof of reactor building with 1600-ton PTC ring crane. Transport with 15-axle platform trailer and tailing with 500-ton hydraulic crane. Doel, Belgium. Completed 2004–06SGT– Steam Generating Team, Duke Energy Oconee 2. Phase 2 – Exchange of 2 x 550-ton steam generators. Outside lifting gantry to position the steam generators on 15 meter high skidtrack. Inside lifting gantry in the reactor building supporting on polar crane rails. Oconee, USA. Completed 2004–03Babcock & Wilcox Oconee. Transport/delivery of 2 steam generators and reactor head. Oconee, USA. Completed 2004–01Bechtel / Rigging International Sequoyah, Unit 1. Exchange of 2 x 380-ton steam generators with 2000- ton capacity crane, Mammoet platform ring crane. Seqouya, USA. Completed 2003–01SGT– Steam Generating Team, Duke Energy Oconee 1. Phase 1 – Exchange of 2 x 550-ton Steam Generators. Outside lifting gantry to position the steam generators on 15 mtr high skidtrack. Inside lifting gantry in the reactor building supporting on polar crane rails. Oconee, USA. Completed 2003–09Babcock & Wilcox Oconee. Transport/delivery of 2 steam generators and reactor head. Oconee, USA. Completed 2003–04Westinghouse Calvert Cliffs Project. Load-out of two nuclear heat exchangers weighing 331 tons at a power station near Baltimore. The job was executed by skidding equipment and conventional trailer for Westinghouse. Baltimore, Maryland, Canada. Completed 2002–07SGT– Steam Generating Team (Morrison Knudsen Corporation / Duke Engineering & Services) Calvert Cliffs 2. Exchange of 2 steam generators with strand jacks, skid system and 4 point lift system. Steam generators exchanged in 2 parts, 200 & 150 tons. Calvertcliffs, USA. Completed 2002–01Mitsubishi Yokohama Tihange 3. Transport of three steam generators. Tihange, Belgium. Completed 2001–01 SGT– Steam Generating Team (Morrison Knudsen Corporation / Duke Engineering & Services)

Calvert Cliffs 1. Exchange of 2 steam generators with strand jacks, skid system and 4 point lift system. Steam generators exchanged in 2 parts, 200 & 150 tons. Calvertcliffs, USA. Completed 2001–01SGT– Steam Generating Team (Morrison Knudsen Corporation / Duke Engineering & Services) Calvert Cliffs Nuclear Power Plant. Offloading of two new steam generators from a barge and transport these pieces to a laydown area. Generators will be dressed before their installation during the exchange shutdown. Calvertcliffs, USA. Completed 2001–01Westinghouse Energy Systems Europe S.A. Tihange 3. Steam generator exchange as part of scheduled maintenance. Tihange, Belgium. Completed 2001–01Indian Point Newark Indian Point 2. Replacement of 4 steam generators, each 350 ton by means of special lifting device. Indian Point, USA. Completed 2000–03Westinghouse Energy Systems Europe S.A. Tihange 2. Exchange of 3 x 475-ton steam generators, each with a length of 24 metres. Hydra Jack lifting system used for exchange. Transportation of the old steam generators to storage area. Tihange, Belgium. Completed 1998–07Westinghouse/PCI Tihange 3. Three steam generators were exchanged in 15 days. Tihange, Belgium. Completed 1998–03SGT– Steam Generating Team (Morrison Knudsen Corporation / Duke Engineering & Services) St. Lucie Nuclear Powerstation 1. Exchange of two Steam Generators using a special temporary lifting device, a tailor-made temporary gantry system, the Hydra Jack system, a skid track and SPMTs. Florida, USA. Completed 1997–12SGT– Steam Generating Team (Morrison Knudsen Corporation / Duke Engineering & Services) Point Beach Nuclear Plant Unit 2. Exchange of two steam generators, consisting of a steam drum, weighing 100 tons and a lower assembly, weighing 185 tons, using a tailor-made lifting and handling device. Point Beach, USA. Completed 1996–11Fabricom S.A Nuclear Powerstation Doel 4. Transport, lifting and installation of three new 453-ton steam generators using skid system and specially designed tailing frame. Doel, Belgium. Completed 1996–07Fabricom S.A. Tihange 1. Three old steam generators were lifted out and replaced by three new steam generators. For this job we manufactured special purpose equipment, such as a skidding system, tailing frame and spreader beam including all engineering. Tihange, Belgium. Completed 1995–07Mitsubishi Heavy Industries Ltd. Tihange 1. Sea transportation, including roll-on/roll-off operation and inland transportation, of 3 x 336-ton steam generators. from MHI Kobe, Japan via Antwerp and Willebroek to Tihange, Belgium. Completed 1995–06 Fabricom S.A. Nuclear powerstation Doel. Site movement and exchange of 3 steam generators, weighing 313 tons each including all engineering. For this job we manufactured special purpose equipment, such as a skidding system, tailing frame and spreaderbeam. Doel, Belgium.Completed 1993–08Siemens KWU Ringhals 2. Site movement and exchange of 3 steam generators, weighing 363 tons each including all engineering. Outside lifting gantry and temporary lifting device on top of polar crane. Ringhals, Sweden. Completed 1988–08

AWARDS AND RECOMMENDATIONS

2005 FPL Turkey Point rector head

exchangePower Engineering Nuclear

Project of the Year

2008St Lucie reactor head

exchangePower Engineering Nuclear

Project of the Year

2009 Diablo Canyon no.1 Steam Generator

Replacement project Pacific Gas and Electric

Company Power-Gen Power Engineering

Nuclear Project of the Year

2009Crystal River Steam

Generator Replacement project

Babcock and Wilcox Letter of Appreciation

2010Olkiluoto Areva Notes of thanks

2013Sellafield Calder Hall Power Station decommissioning

HertelLetter of Appreciation

2013 Sellafied Evap D Project

Costain Oil, Gas & Process Ltd Costain ‘Achieving

Excellence’ Award for Supply Chain

Partner Of The Year 2013

2013Pipe bridge installation,

SellafieldShepley Engineers

Letter of Recommendation

2013Sellafield Calder Hall Power Station decommissioning

Sellafield Ltd Nuclear Letter of Recommendation

2014Chernobyl Safe Confinement

Novarka European Association of Abnormal

Road Transport and Mobile Cranes Innovation Award

NU

CLE

AR

RE

FER

EN

CE

LIS

T


GLOBAL PRESENCE

8

5

12

Would you like to get in touch?Please find your nearest Mammoet regional head office here.

1 MAMMOET CANADA WEST

Head Office: Edmonton, Alberta CanadaTelephone: +1 780 449 0552E-mail: [email protected]

2 MAMMOET CANADA EAST

Head Office: Puslinsch, Ontario, CanadaTelephone: +1 519 740 0550E-mail: [email protected]

3 MAMMOET EUROPE

Office: Schiedam, the NetherlandsTelephone: +31 10 204 2740Email: [email protected]

4 MAMMOET RUSSIA

Office: Moscow, RussiaTelephone: +7 495 956 08 38E-mail: [email protected]

5 MAMMOET USA

Office: Rosharon, USATelephone: +1 281 369 2200E-mail: [email protected]

mammoet insight · 2019-09-06 · at mammoet, we provide solutions for lifting, transporting,...

Documents