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CASE STUDY

600t AUTOCLAVE

TRANSPORTATION FROM PETKIM

PORT TO GORDES

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CONTENTS

• PROJECT INFORMATION

• LOAD DETAILS

• TRANSPORT ROUTE

• TRANSPORT CONFIGURATION

• TECHNICAL DETAILS OF TRAILER

• REASONS FOR CHOOSING SPMT

• OBSTACLES ON THE ROUTE

• TRANSPORT OPERATION

• INSTALLATION OPERATION

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3 Sayfa

• Project area: Mine site is 20 km away from Gördes Town by an asphalt road and it is

nearly 45 km from Akhisar Town, 115 km from Manisa and 180 km from İzmir Aliaga

Petkim Port. The nearest state railway is about 40 km away.

• A total of 230,000 tons of nickel ore was produced from two open pits and 150,000

tons of ore was exported to Greece, Macedonia and China, since 2003.

Approximately 80,000 tons of the remained nickel ore was stocked at the mine site,

to be used during trial production of the process plant, which is under construction.

• After several researches Meta Nickel Management decided to use HPAL (High

Pressure Acid Leaching) process with 255 C° and 55 bar pressure to separate

Nickel.This is the latest technology to produce nickel and cobalt cakes with low acid

usage and environment protections. That’s why an Autoclave ordered to Morimatsu

Nantong.

PROJECT INFORMATION

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• MAIN CONTRACTOR: META NICKEL

• SUBCONTRACTOR:PANALPINA WORLD TRANSPORT

• TRANSPORT CONTRACTOR: HAREKET HEAVY TRANSPORT

PROJECT INFORMATION

SCOPE OF HAREKET

• ROUTE SURVEY AND PLANING

• TRANSPORT 600T AUTOCLAVE FROM PETKIM PORT TO GORDES JOB SITE

• INSTALLATION CARGO ONTO FOUNDATION

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LOAD DETAILS Autoclave weight :600 tones

Dimensions :L = 34 m W = 7.05 m H = 7.15 m

Loaded height :H = 8.15 m

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TRANSPORT ROUTE

• Petkim Port-Aliağa-Bergama-Kınık-Soma-Akhisar-Gördes Job site

• Total 180 km

• 335 critical points

• %12 percentage slopes and downhills

• All route survey done with gps system

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TRANSPORT CONFIGURATION

• 22 Axle 3 File Goldhofer PST/SL-E hydraulic trailer

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• Traction Force Calculation

PST/SL-E Driving Performance Data with PFV 490/60-31

PST/SL-E Fahrleistungsdaten mit PFV 490/60-31

Combination Selection Kombinationszusammenstellung

PST

/SL-

E

33 66 x 24

Standard - SL-E - Modules Units Anzahl

Driven

AL Antr.-

Ali.

DW/Module EG/Modul

Deadweight

total EG

gesamt

Powerpacks PFV 490/60-31 2 - - - 7.500 kg 15.000 kg

SL-E 4-08x02 1 driven AL 1 1 17.300 kg 17.300 kg


SL-E 8-16x04 2 driven AL 0 0 33.700 kg 0 kg

SL-E 4-08x00 split 0 driven AL 0,5 0 17.500 kg 8.750 kg


SL-E 8/6-12x04 2 driven

AL 0 0 29.100 kg 0 kg

more (+) or less (-) driven axle

lines

5 460 kg 2.300 kg mehr (+) oder weniger (-) angetriebene Achslinien

Non-driven THP/SL axle

lines

0 - - - 3.400 kg 0 kg nicht angetriebene THP/SL Achslinien

Additional equipment (e.g. P-consoles, decks, etc.) Zubehör (z.B. P-

Konsolen) 680 kg

Axle lines total Anzahl Achslinien gesamt 33 AL

thereof driven axle lines davon angetriebene Achslinien 12 AL

Technical Data Technische Daten

Deadweight Eigengewicht 159.680 kg

Axle load unladen Achslast unbeladen 4.900 kg

Selected laden axle load ausgewählte beladene Achslast (ma

x. 45.000 kg) 23.021 kg

Gross weight Gesamtgewicht 759.680 kg

Payload approx. Nutzlast ca. 600.000 kg

Driving Performance Data Fahrleistungsdaten

Rolling resistance factor Rollwiderstand

5,0 % Traction factor Kraftschlussbeiwert

50 %

Empty Drive Leerfahrt

Driven axle lines angetriebene Achslinien 4 8 12 AL

Max. speed level ground Max. Geschwindigkeit Ebene 14,1 7,8 5,3 km/h

Laden Drive Lastfahrt



Max. grade max. Steigung 1,3 7,6 14,0 %

Speed on max. grade Geschwindigkeit max. Steigung 3,4 1,7 1,1 km/h

Max. tractive force max. Zugkraft )* 118 kN/AL 471 942 1.413 kN

Max. speed selected grade ausgewählte Steigung 12,0 % 0,0 0,0 1,3 km/h

Max. speed of tire max. Geschw. des Reifens 15,0 km/h

PST/SL-E Driving Performance Data with PFV 490/60-31

PST/SL-E Fahrleistungsdaten mit PFV 490/60-31

Combination Selection Kombinationszusammenstellung

PST

/SL-

E

33 66 x 24

Standard - SL-E - Modules Units Anzahl

Driven

AL Antr.-

Ali.

DW/Module EG/Modul

Deadweight

total EG

gesamt

Powerpacks PFV 490/60-31 2 - - - 7.500 kg 15.000 kg



SL-E 8-16x04 2 driven AL 0 0 33.700 kg 0 kg



SL-E 8/6-12x04 2 driven

AL 0 0 29.100 kg 0 kg

more (+) or less (-) driven axle

lines

5 460 kg 2.300 kg mehr (+) oder weniger (-) angetriebene Achslinien

Non-driven THP/SL axle

lines

0 - - - 3.400 kg 0 kg nicht angetriebene THP/SL Achslinien

Additional equipment (e.g. P-consoles, decks, etc.) Zubehör (z.B. P-

Konsolen) 680 kg

Axle lines total Anzahl Achslinien gesamt 33 AL

thereof driven axle lines davon angetriebene Achslinien 12 AL

Technical Data Technische Daten

Deadweight Eigengewicht 159.680 kg

Axle load unladen Achslast unbeladen 4.900 kg

Selected laden axle load ausgewählte beladene Achslast (ma

x. 45.000 kg) 23.021 kg

Gross weight Gesamtgewicht 759.680 kg

Payload approx. Nutzlast ca. 600.000 kg

Driving Performance Data Fahrleistungsdaten

Rolling resistance factor Rollwiderstand

5,0 % Traction factor Kraftschlussbeiwert

70 %

Empty Drive Leerfahrt



Laden Drive Lastfahrt



Max. grade max. Steigung 3,5 12,0 20,5 %

Speed on max. grade Geschwindigkeit max. Steigung 2,1 1,1 0,7 km/h

Max. tractive force max. Zugkraft )* 159 kN/AL 634 1.269 1.903 kN

Max. speed selected grade ausgewählte Steigung 12,0 % 0,0 1,1 1,3 km/h

Max. speed of tire max. Geschw. des Reifens 15,0 km/h

Graveled Road Paved Road

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Permenant Saddles

Temporary Saddles

• Saddle Design

Transport Beam

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TECHNICAL DETAILS OF TRAILER

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REASONS FOR CHOSING SPMT

• Steering possibilities and less construction works on the route acc. to conventional

hydraulic trailer that are pulled by prime movers.

• 12 unit tyres per axle line-4 unit tyre per axle line more than 2.44m width spmt trailers

• Less loading height and less cable obstacles on the route

• No need big crane for installation at site

• %12 percentage slopes on the route.

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Bridge by pass constructions 11 unit Removed Electricity and Telephone Cables 280 unit Removed Pedestrian Overpass Bridge 2 unit Road widening constructions 20 unit Removed Traffic Light 16 unit Removed Camera Tower and Traffic Signs 6 unit

OBSTACLES ON THE ROUTE

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RECEIVE AUTOCLAVE ONTO TRAILER (SPMT)

Autoclave Discharge Operation in the Petkim Port, Aliaga Izmir, on 26 Apr 2013 Geared

vessel from SAL with a combined lift capacity of 1500 ton was engaged. Goldhofer

PST/SL-E (also called SPMT) placed along side vessel to receive the 600 ton autoclave

TRANSPORT OPERATION

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The exit route is challenging since we have to manage 5 x 90 degree turns on route inside

Petkim Factory. The basic road profile and structure is suitable but improvements are

needed at some locations. Steel plates and filling material will be kept on stand by, so that

same can be used up on request.

TRANSPORT OPERATION

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TRANSPORT OPERATION Turnings inside Petkim Factory.

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Snap shot showing one of the first by pass road constructions with the autoclave convoy in

position to cross over. Each and every by pass construction was different and a detailed

engineering plan was established to identify number of pipes, filling material, and time

frame for construction

TRANSPORT OPERATION

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• Detailed Road Survey Done for the possible obstacles on our way.

• Applied to (KGM) Road Dept. of TR HQ for the road permissions and removing

permissions of two overpass pedestrian bridges.

• For 11 Bridges loading test reports prepared , application projects drawn and applied to

( DSI ) Government Water Supply Department for By-Pass Road construction

permissions.

• All of these preparations, planning's and surveys took 18 mounts of labor and

countless meetings in Shanghai ,Izmir , Gordes , Ankara and Memmingen.

TRANSPORT OPERATION

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Two pedestrian crossings had to be partially removed while on route from port to job

site. Dismantling extent and method was studies well in advance to identify equipment

needs and time consumption

TRANSPORT OPERATION

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The Last By-Pass Construction on

Medar Creek

TRANSPORT OPERATION

600t Autoclave on the main road

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Sample Drawings for Mountain Road Journey

TRANSPORT OPERATION

All route at mountain road are checked with gps and turning simulation is made on

Autocad programme and minimum backfilling and widening works planned.

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Sample Drawings for Mountain Road Journey

TRANSPORT OPERATION

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`The beginning of the “mountain road” was

narrow, winding and had an incline of up to 12

%. The fuel consumption of the SPMT at this

location and with 750 ton gross weight is

around 80 liter per km.

TRANSPORT OPERATION

Before transportation, journey plan is made,

and all parking points are defined and 11 unit

parking place is constructed.

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A number of corners on route had to be extended significantly to accommodate the convoy

as shown below. The road extension work has to be removed again once the convoy

passed by to comply with instructions from the road safety department

TRANSPORT OPERATION

Autoclave transported

from sea level up to

totally 1500m altitude

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Remember …! Everybody who was part of the SPMT operation and supervision had to

walk the whole distance of 180 km. Below a snap shot at km 155.

TRANSPORT OPERATION

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Road and air temperatures rose every day a bid more and we had only a few hours

available per day to move the convoy. Usually the convoy started to move at 04: 30 AM and

stopped prior to noon. Water tankers were engaged to spray water and to cool the road

down as much as possible to prevent melting of asphalt.

TRANSPORT OPERATION

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After 64 days on route convoy makes its approach to the temporary foundation. The

autoclave needs to be offloaded in order to place the autoclave onto final foundation and to

reconfigure the SPMT

TRANSPORT OPERATION

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Autoclave is now placed on temporary storage supports or also called

“elephant legs” SPMT is removed from under the autoclave and will be

reconfigured.

INSTALLATION OPERATION

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The transfer of the autoclave from the temporary foundation onto final foundation

required a number of different step and scopes. Each of the scopes had to be

engineered well in advance and in detail which sounds easier than it is.


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Permanent foundation received

final touch in order to receive the

autoclave

Ground preparation work between

the temporary and permanent

foundation was completed in time

and left to rest over night.


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Day 67 autoclave was loaded onto SPMT’s early in the morning and as per plan and

schedule. Autoclave was lashed and secured once total weight was transferred onto

SPMT’s. The transfer operation was executed as planned and without any problems


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Final line with permanent

foundation required experience

and patient

The actual space available between the bolts

and the bolt holes was =/- 5mm only. The 746

tons are lined up with all 48 bolts with a

accuracy of +/- 5 mm… ready to place

autoclave slowly onto its final foundation


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Autoclave was delivered on to permanent foundations on 30.06.2013 at

17:00 without any incident.


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THANKS TO META NICKEL AND PANALPINA WORLD TRANSPORT FOR THEIR TRUST AND

GIVING CHANCE TO HAREKET HEAVY LIFTING AND PROJECT TRANSPORTATION COMPANY

FOR SUCH A CHALLENGING TRANSPORTATION JOB.

.

Gordes 580t otoklav hareket rev2 21.01.2014.mp4

hareket - apaweb.net · hareket sayfa3 • project area: ... goldhofer pst/sl-e (also called spmt)...

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