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Mammoet, the global market leader in heavy lifting and transport, is performing all transport and lifting work for the Fujairah F3 Power Generation Project, the UAE’s largest stand-alone combined cycle power plant.
Located 300km northeast of Abu Dhabi, the 2.4GW plant is being developed as an Independent Power Plant (IPP) project using efficient combined cycle technology and will make a significant contribution to the country’s power generation sector.
Samsung C&T, the EPC general contractor for the project, was awarded the scope of receipt, transportation, hoisting and installation of Mammoet power plant components, including three gas turbines with the largest capacity and highest efficiency in the UAE.
Safe and timely execution
The company’s long track record of executing projects in the country in a safe and timely manner – particularly in the Critical Infrastructure and Coast Protection Agency (CICPA) area – led Mammoet to be responsible for the project’s heavy and oversized cargo.
Abu Dhabi Ports’ Fujairah Terminal, operating at the Port of Fujairah under a concession agreement, was selected as the most suitable port for receiving and handling oversized cargo due to its location, avoiding the steep Fujairah The mountain slopes, infrastructure and technical capabilities of the Fujairah terminal.
A total of 105 power plant components will need to be transported 23 kilometers from Fujairah Port to the project site at the Fujairah Hydropower Complex at Qidfa. The only feasible route to connect the port to the power station presented a challenge that needed to be addressed before transport could begin. Other route options are too restrictive when passing through the inland mountains.
Challenges and Routes
The route has a viaduct with a maximum clearance of 7.3 m, while some components (such as the gas turbine) require a clearance of 7.5 m, including the trailer. To get the cargo over the viaduct, Mammoet engineers opted to load the turbines directly onto the trailer instead of using standard transport beams. This lowered the overall transport height by around 30cm, but meant that the load could not be unloaded onto the stool for temporary storage and needed to be lifted from the trailer and installed directly on site.
Detailed engineering, thoughtful planning, and timely acquisition of required approvals and permits, including CICPA pass, enabled all components to be delivered to site safely and on time. Three gas turbines with a length of 13.6 meters, a width of 6.1 meters, a height of 6 meters and a weight of 528 tons, and three gas turbine generator sets with a length of 11 meters, a width of 5.8 meters, a height of 5.2 meters and a weight of 395 tons were delivered to the site and safely crossed the bridge Down. They were then hoisted from the trailer and mounted directly to the foundation using Mammoet’s gantries.
In addition, Mammoet used its 1,250-ton and two 400-ton crawler cranes to install additional components, including 45 modules for the heat recovery steam generator (HRSG). Each module weighs 338 tons and needs to be removed from the transport frame before being installed in the HRSG unit.
Safety culture
Mammoet was recognized for its safety culture and contribution to the 3 million safety man-hours on the Fujairah F3 project.
Fujairah F3 is located in the Qidfa area of Fujairah, between the existing Fujairah F1 and Fujairah F2 hydropower plants and, once operational, will be able to power the equivalent of 380,000 homes. It will feature advanced “JAC” class gas turbine technology and will utilize the most efficient combined cycle technology in the region. — trade arab news agency
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