Hindustan Petroleum Corporation Limited (HPCL), Mumbai refinery wanted to upgrade their plant adhering to the strict Euro 3 emission norms. To align with auto fuel policy, HPCL decided to add a Diesel Hydro Desulphurisation (DHDS) plant for producing diesel of Euro III quality. As a part of this project, they decided to install a new DHDS reactor at its operational refinery at Mahul, Mumbai.
HPCL wanted to install the reactor without shutting down other units in their said refinery. The other challenge was scarcity of space since the reactor needed to be installed in a congested area of the plant. To install the reactor using a crane or by towers with guy ropes was not possible due to scarcity of space and adjoining structures. Also, the space required for tailing the reactor with a crane during operation was not feasible. Therefore, HPCL was looking for a non-crane lifting solution. HPCL had given the contract of fabrication, supply and installation of this reactor measuring 30m x 3.6m x 3.6m to M/s Larsen & Toubro, Hazira.
The team at Freight Wings presented a customized non-crane, non-guyed tower alternate lifting solution to L&T by proposing lifting with free standing tower, strand jacks and tailing by tailing frame mounted on hydraulic axles. The engineered solution comprised of twin sets of modular lifting towers, lifting girders, computer controlled strand jack operated by diesel- driven power pack. They also transported the reactor from its storage area within the refinery to under the lifting hook of their strand jack tower system. After lifting the reactor, it was skidded towards its foundation by push-pull hydraulic cylinder system mounted on the top girder.
During upending of reactor, the team used a customized tailing frame. The frame was mounted on hydraulic axles and the lifting/tailing operation was coordinated precisely in such a way that lifting speed and movement of the hydraulic axles were synchronized. The lift was executed in six hours and the reactor was placed on to its foundation safely, to the client’s satisfaction.