Operations at existing sites
Operations at existing sites present their own challenges. Minimizing down time, restricted
space to move around, safety procedures, it is all familiar to Mammoet.
Shut down and maintenance
A shut down disturbs the production process at a
chemical plant. The down time must be kept to
a minimum, and careful pre-engineering, logistics
and planning can optimize this. Mammoet often
plays a pivotal role in the design of scheduling.
Our representatives easily communicate within any
specialists team.
A notable complication in many shut down and
maintenance projects is the often very limited space
to move around. It could be necessary to lift items
at a very large radius. Mammoets big cranes, fitted
with the proper booms, luffing jibs and super lift
configurations with counterweights, are up to these
tasks. Depending on the allowable limits for ground
pressure, space to rig a crane and the need for
relocation of the crane, Mammoet may select
between crawler cranes, ringer cranes and lifting
gantries. Besides, there are various options for the
tailing problem as large columns are erected.
A tailing crane could work in tandem with the main
crane. Mammoet also developed a tailing frame,
supported by SPMTs, that moves synchronously
with the main lift.
Maintenance is an ongoing process. Mammoet
developed long term maintenance contracts that
ensure uninterrupted availability of equipment
capacity and crews, flexibility in scheduling,
continuous access to our engineering resources
and the assurance that skilled experts can be called
upon to assist with handling unexpected situations.
Live plants and safety
Live plants require demanding safety procedures
to be in effect. Any handling of the load needs pre-
engineering to verify that safety constraints are
never violated. Extensive risk analysis is executed
in cooperation with the customers representatives
and our own safety officers. They are responsible
for any safety and security related task and have
the experience and authorization to decide about
go or no-go of any operation. To us, safety also
means to ensure the integrity of the costly modules
and equipment. Especially during transports that
may go overseas, through deserts or densely
populated areas, the safety regulations require an
extensive pre-survey of any route and road that is
included in the trajectory. Where needed, precau-
tions are taken like the temporary removal of items
along the road, or the extra sea fastening onboard
a heavy lift ship or barge.
Equipment setting
The factory-to-foundation concept of Mammoet
includes additional services that cover the total
chain from end-to-end. A striking example is the
exact positioning of modules. The allowable
tolerances are often just millimeters. Mammoet
developed special techniques for shimming huge
objects with small steel plates such that the
attitude, location and elevation come close to
the ideal values for these parameters.
On-site engineering
Mammoet is renowned for the ability of its staff
and crew to cope with unexpected circumstances.
But our improvisation never leads to unacceptable
safety levels because we apply on-site engineering.
This may be regarded as a temporary extension of
Mammoets engineering resources to the site itself.
Information and communication technology greatly
enhances this service. It also facilitates data
management and supports engineering training
of our specialists at remote sites.
Mammoet provides tailor made solutions in heavy lifting and transport. A company with Dutch roots, the enter-
prise has evolved to a world-class player that sets trends and records. Activities focus on the petrochemical
industry, civil projects, power plant facilities, offshore business and marine projects.

www.mammoet.com
 Worldwide specialists in heavy lifting and transport

Partner in petrochemical projects

Mammoet and the petrochemical industry

Mammoet provides tailor made heavy lift and transport

solutions. In the petrochemical sector, the optimization of

performance ratios forces companies to proceed with up-

scaling of their facilities, both at existing and new-construction

sites. This implies a need for more and larger modules like

columns, reactors, pipe racks and flare stacks. Whatever their

dimensions and weights are, these modules must be

transported and positioned before they can be put to work.

The accomplishment of these tasks belongs to the core

business of Mammoet.

State-of-the-art equipment and loyal professionals in staff and

crews are our main assets, complementary to our advanced

engineering ‘think tank’ and high level safety regulations.

These ensure the successful accomplishment of end-to-end

services as main contractor, subcontractor, as well as of rental

services and equipment trading.

Safe the delivery of eight tanks
Customer: Alliani Location: Ravenna, Italy Main equipment: SPMTs en barges

Highlight: Mammoet Italy won the contract for the transport over water and load-out of 8 tanks, using 24 axle lines of

SPMTs at the Enichem plant in Ravenna. The water transport called for two consecutive barge trips with 4 tanks each.

The load-out was done on a gas loading jetty and required high safety precautions. When a tank was due or berthed

at the jetty, all normal operations were suspended. Upon unloading, six tanks were transported to a storage area at

250 meter distance and delivered on temporary supports. The remaining two tanks were positioned directly on sand

foundations.
 Focus on petrochemical plants
Mammoet established an impressive track record in the petrochemical sector that covers
one-of-a-kind projects and day-to-day ‘routine’ operations. Safety is a leading issue at
any time.
Worldwide and local dimensions
The global presence of Mammoet comes with
regional and local establishments or representatives.
Moreover, the availability of equipment ‘at arms
length’ in every part of the world is vital to our
proper network for effective management of factory-
to-foundation projects. Contracts are also awarded
for our specific services that require highly specialized
skills, expertise and equipment. A few examples are
the handling of outsized cargo, operations in live
plants and jobs to be carried out in very small
spaces with severe limitations for ground loads.
In such cases, our specially own-developed sup-
portive equipment like tailing frames, ring cranes
or gantry systems are at the heart of Mammoet
solutions. Rental activities to provide extra on-site
craneage complete our range of services for the
petrochemical sector.
Typical projects
A representative sample of typical Mammoet
solutions includes:
• Construction of plants at new development sites.
• Relocation of existing plants. This may be
triggered for environmental and demographic
reasons, or from inadequate space to increase
the production capacity at the current site.
• Extensions with additional processing units.
Such projects may pose safety issues, especially
if parts of the plant stay ‘live’.
• Upgrading of existing facilities. Upgrades often
take place in live plants and thus require special
safety procedures.
• Maintenance processes during the shut down of
facilities and the exchange of used modules with
replacement units.
Renowned equipment and engineering
Extraordinary challenges require extraordinary tools
to address these. The available equipment range is
fascinating and includes the worlds biggest cranes
(hydraulic, telescopic, crawler, ring, floating), the
largest fleet of transporters (conventional, SPMTs),
gantry systems, strand jack equipment, weighing,
skidding and ballasting systems to facilitate load-
outs and load-ins. These tools, with our highly
experienced, skilled crews and our ‘think tank’ of
engineers, are our main assets. The engineering
phase yields sophisticated manuals, logistics plan-
ning, equipment planning, crew scheduling, risk
analyses and cost reviews. The latter is extremely
important, since the choice of the solution concept
determines the majority of cost.
Safety first
All operations carried out throughout the world by
Mammoet must comply with the QSE standards
(Quality, Safety & Environment) for health, safety,
environmental care and the quality of the technical
performance. Examples of ‘tools’ that go with QSE
are safety manuals, assessments of risk, methods
and procedures, safety guidelines, audits, on-site
inspections and tool-box meetings.
Exchange in crowded space
Customer: Shell Nederland Raffinaderij B.V. Location: Pernis/Rotterdam, The Netherlands

Main equipment: PTC, LR 1250, SPMTs Highlight: In March 2001, Mammoet received a request from the ‘Halt

preparation Shell-Pernis’ to prepare a plan for exchanging a regenerator head with cyclones, at a weight of 350 tons

and a reactor in two parts, of 225 tons each. After preparing measurements and drawings, Mammoet initially offered

to execute this job with the CC-4800 crane. But after meetings with Shell and engineering bureau Jacobs, the weights

were adapted and Mammoet was asked to replace the whole reactor.
Relocating a mammoth tank
Customer: Shell Refinery Location: Port Dickson, Malaysia Main equipment: jacking system, SPMTs

Highlight: A new extension of the plant required the relocation of a 16 year old storage tank. The double deck floating roof tank weighed 1,500

tons and was quite large; 70 meters in diameter and 23 meters high. Engineering showed it could be moved on SPMTs along a specially prepared

and 650 meters long road. The tank was reinforced with an internal octagonal truss structure. A second structure was installed to fix the roof

while a third structure would provide adequate support and interface to the SPMTs. The jacking procedure followed a cycle of pushing up the tank

gently stop by stop, and adding additional blocks to enlarge the stoppings. Once elevated 2.4 meters, the 16 units of SPMTs took position. As the

computer controlled stack proceeded with a speed of 150 meters per hour, the jacks of the SPMTs compensated for the 3 meters slope along the

road to keep the tank level. At the new location, the jacking procedure was reversed, delivering the tank on new foundations.
Gantry system in a live plant
Customer: Valero Refining Company Location: Benicia, California USA Main equipment: Strand jacks, gantry system, lifting beams

Highlight: A 33 meters high Vacuum Distillation Column of 450 tons needed to be replaced in a turnaround. It is a critical piece of equip-

ment as it processes 50 percent of the crude oil at the site. To comply with the strict safety rules at the live plant, a gantry lift system was

selected. It comprised six tower sections and load beams, allowing for north-south, east-west, up-down and rotation moves. The beams

could handle 740 tons each, but loads on the soil were nevertheless kept to a minimum without applying counter weights.
Versatile equipment for new construction
Customer: ABB Lummus Global B.V. Location: Rotterdam, The Netherlands Main equipment: Hydraulic cranes, crawler cranes,

SPMTs, CC 2800 Highlight: The PO-11 project is an example of Mammoets support during the construction of a new petrochemical

plant. The complex project, for which ABB Lummus Global B.V. is prime responsible, called for various contracts to supply cranes, trans-

port equipment and rigging crews. These supported the construction of foundations, the installation of pipe racks, of steel constructions,

and of storage tanks. The special Equipment Erection Contract covered the complete logistics for handling more than 400 items up to

390 tons. The logistics included offloading, site transports, storage and retrieval, positioning, shimming and alignment. A steel plate road

of 950 meters long and 7 meters wide eased the SPMT moves, while a CC 2800 erected a 165 meter high flare stack.
 New development sites
The manufacturing of equipment for petrochemical plants is done with specialized facilities
to machine, weld and assemble modules like pipe racks, columns, storage tanks, flare
stacks, furnaces and processing units. Activities on the site itself are focused on layout
preparation, foundations, final dressing of modules, assembly of larger parts and the
commissioning of ready-to-go facilities. But these represent only the final stages of a long
chain of activities that starts at numerous yards all over the world.

Factory-to-foundation concept Relocation

The factory-to-foundation concept is applicable to Relocation of a processing unit, or the haul of
new development sites and operations on existing complete production plants, are challenges in itself.
sites. It can be compared with completing a puzzle. Units are taken apart to dimensions and weights
Many small items must be brought together and that can be lifted and moved. At the new site, this
there is only one perfect match to discover. procedure is reversed and the facilities are rebuilt.
If dozens of modules are involved, the main Relocations need support by a host of big and
contractor for all integrated transport and lifting small cranes, as well as transport equipment,
issues must have a global scope and strong transport frames, heavy lift ships, sea going barges
regional or even local ties and representatives. and other means to realize multi modal transport
This is just what Mammoet offers. An optimized solutions. Such projects push logistics to the limits.
and integrated solution for engineering, opera- Mammoet gained extensive experience with relo-
tions, logistics, equipment commissioning and crew cating complete plants can do this in reasonable
assignments, greatly reduces the total project cost. time because resources in equipment and crew
are always sufficiently available. Rental services
Modular construction often relieve the pressure on other subcontractors
To control cost and to minimize risk with complicat- resources and provide ample redundancy to cope
ed operations at remote areas, many modules are with unexpected complications.
pre-assembled to larger parts at their yards-of-birth.
This modular concept is highly successful due to
the good options for transport and lifting at both
the yard and the production site. An example is the
dressing of modules. These arrive in a casco-state
and are delivered to a temporary storage area at
the destination site. Subsequently, appendages are
installed with the support of smaller cranes to
complete the stack ready for a final site-move and
delivery onto its foundations. Site-moves can be
achieved with Mammoets huge crawler cranes, with
SPMTs or with skidding and jacking techniques.