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Mammoet supported a leading Canadian energy provider in Alberta’s oil sands since 1967, with replacing its original 8 coke drums at its Base Plant site in Fort McMurray. The project would extend the life of the original upgrader by 30 years. The site upgraders use thermal and chemical processes – including coking and hydrotreating – to convert bitumen into synthetic crude oil. Coke drums gather the petroleum coke that is separated from the feedstock during the refining process. Weighing 270 t a piece, each coke drum is 7.9 m in diameter and 29.8 m high. Moving them into place required one of the largest cranes in the world. Through early involvement, Mammoet was able to advise on the right crane for the job and, when one of the new components was heavier than estimated, they fabricated specialized rigging for the lift. The team also helped accelerate the schedule by shortening the time between two of the biggest lifts of the project – helping enable the upgrader’s early return to operation. Choosing the right tools for the job “In terms of the importance of the project and getting everything done within a specific timeline, this turnaround was completed safely, ahead of budget and schedule,” explained Kurt Reid, sales manager at Mammoet. “With the daily cost being significant, it was essential that planning happened years in advance.”
The engineering team first considered using an LR 11350 crawler crane placed beside an upgrader wall, but the option was not feasible because it interfered with concurrent operations and maintenance work in the area. Therefore, Mammoet’s PTC210DS ring crane was selected. It has the capacity to not only lift the heaviest component (a 6-drum derrick weighing over 1,200 t) but, thanks to its impressive reach capacity, could be assembled further away to not disrupt other on-site work. As the PTC had to be erected inside the coke pit, civil work was needed to strengthen the ground beneath it. Around 200 piles were driven into the ground to build a solid foundation.
This process started a year and a half before the project area would shut down for execution. “Our plan was to have everything the company needed – equipment, materials and components – on site by December 2024 so that on May 1st when the plant was shut down, the turnaround could begin without interruption. The crane was assembled, the coke drums and derricks were on site, everything was there months ahead of time. This allowed us to eliminate delays mid-project,” explained Niek de Winter, Corporate Account manager at Mammoet. On site, 2 sets of SPMTs and crews (each running a day and night shift) allowed things to move forward continuously and the PTC crane to be constantly fed. The old derricks (a 2-drum and 6-drum) were lifted first, followed by the 8 coke drums and finally their concrete foundation sections. The old components were placed onto SPMTs and driven to a nearby laydown area for decommissioning. For the installation of the new components, the process then happened in reverse.
The base of these supermodules made up the operating deck of the coke drums and were assembled via SPMT from the smaller modules. The derricks were erected with Mammoet crawler cranes. Due to a weight increase of the largest derrick supermodule, the project team at Mammoet had to maximize use of the PTC210 to deliver the needed lifting capacity. It was reconfigured with a double masthead kit, and specialized rigging was also fabricated. Accelerating the schedule From factory to foundation, Mammoet safely and efficiently managed its components on site ahead of the turnaround. “As soon as we are called on, we are ready to perform the next lift,” concluded Mr. Reid. “When you have a client that is planning their multi-week event right down to 15-minute intervals, time is of the essence.”
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Coke Drum Integrity Project Completed 
Mammoet was an integral part of the project for over 7 years prior to execution, discussing the timing of lifts and movements. Its engineers undertook an entire crane review, assessing every suitable model in Mammoet’s fleet to select the right equipment for the jobs. The biggest consideration was not weight, but reach. 
Getting everything ready and in place
The 4th deck derrick ‘supermodules’ – named for their mammoth size – were transported to the facility in smaller modular sections and then moved and assembled on site.
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