Huge reactor installed with military precision

A key component of the current SAPREF refinery shutdown, the replacement of a reactor on one of the process units, has been successfully completed. At a cost of R138 million, this is the single biggest project of the planned major maintenance shutdown.

“With a length of 32 metres and a weight of 171 tonnes, the installation of the reactor was a carefully planned exercise, particularly as it was carried out within a confined space and at considerable height,” said SAPREF project manager, Ebrahim Vawda. “The lift started in the early hours of the morning to take advantage of the calm weather conditions and low wind speed.”

Two giant Sarens cranes, an 800 ton crawler crane and a 440 ton hydraulic crane, were used to remove the old reactor and lift the new unit some 35 metres onto a structural steel base in the refinery.

These cranes are among a total of 36 cranes on site for the shutdown. “This is a record number of cranes to have on one site at any one time in Durban,” said Mike Swanepoel, supervisor at Johnson Crane Hire. “The cranes are being used in a variety of lifts, such as removing equipment and installing new piping, columns and vessels.”

SAPREF, which is southern Africa’s largest crude oil refinery, has a major shutdown every four years to ensure the safety, reliability and integrity of its equipment. The full cost of the shutdown is about R800 million. More than 2500 contract jobs have been created.

For more information, contact:
Lindiwe Khuzwayo
Sustainable Development Manager
Tel: 031 480 1750
Cell: 082 883 6329
Email: khuzwal@sapref.com