Construction World October 2016

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CONSTRUCTION WORLD OCTOBER 2016
instrumentation construction and mainte-
nance of process plants for Sasol in Secunda
since 2009 and in Sasolburg since 2011.
In comparison to the Sasol Secunda
operation the Sasolburg operation is
certainly smaller, however the division has
been relatively successful in ensuring the
continuity of projects at both locations, here,
in particular within the maintenance sphere.
“Retaining the best core team in the market
is our constant goal,” says August Lipke,
operations director for the division. “Based
on our experience and performance, we have
successfully negotiated a number of E&I
maintenance and construction contracts.”
These include:
• FTWEP Phase 2 (Sasolburg)
• Work pack 01 and 04 E&I (FWSA);
• WP 01/04 Steam Tracing in conjunction
with Stefanutti Stocks Oil & Gas division;
• FTWEP Work Pack 05 & 07 (Linde); and
• DMR (for Worley Parsons) (Sasolburg)
• Medium Voltage and Instrumentation
maintenance (Sasolburg)
• Electrical and Instrumentation
Maintenance (Secunda)
• Plant Light Maintenance (Secunda)
• VOC Expansion Project (Secunda) in
conjunction with Murray & Robberts
• Coal tar Filtration East (Secunda) in
conjunction with Stefanutti Stocks Oil &
Gas division
A recent highlight included the achivement
of a 1,5 million LTIFR milestone by the Stefa-
nutti Stocks’ Electrical & Instrumentation
team that has been undertaking the main-
tenance of Sasol Secunda’s process plant
equipment and plant lights since 2009.
E&I installation
Stefanutti Stocks Electrical and Instrumen-
tation (E&I) annually undertakes multiple
projects for Sasol Synfuels and recently
undertook the E&I revamp of the Sasol’s Poly-
propylene Plant (PP2) unit located in Sasol’s
Secunda complex. The project, entitled the
C3 Expansion Project sees the capacity of the
C3 process equipment increase from 300 ktpa
to 375 ktpa.
The pre-shutdown work included:
• Preparatory work during which
equipment and services were prepared
for the shutdown and changeover.
• The installation of new cableways and
support.
• Pulling in of new cable.
• The installation of new equipment.
• Switching off and removing existing
equipment for refurbishment (typically
drives, instruments and switchgear).
Some of this equipment was refurbished
on site, or in the case of the more
complicated functions, carried out by
Original Equipment (OEM’s) off site.
Shutdown work included the testing, rein-
stallation, reconnection, commissioning and
re-integration of the refurbished equipment
into the operational plant. A total of 200 kilo-
metres of cabling and 140 instruments were
installed during the project.
Specialised grouting
Stefanutti Stocks Civils’ niche capabilities
include foaming agents, cementitious
grouting, epoxy grouting, bentonites, cavity
filling foundation colgrouting and marine
concreting. The division recently undertook
a specialised grouting project for Aveng
Grinaker LTA at Sasol Secunda’s selective
catalytic cracker (SCC) plant.
Epoxy grout was applied to the pump
and compressor bases in the SCC that
outputs ethylene and propylene. This
particular type of grout is utilised in harsh
commercial and industrial applications or in
areas exposed to chemicals. Cementitious
grouting, designed for static or light dynamic
loading (or high temperature exposure), was
applied to all instrumentation baseplates
within the SCC.
Concrete rehabilitation
and repair
Stefanutti Stocks Civils recently completed
the repair to the rim of a cooling tower for
Sasol Synfuels in Secunda. The work area
on top of the 165-metre-high cooling tower
was accessed by means of an Alimak Scando
20/30 construction hoist that was used to
transport all equipment and personnel up to
the top platform. The project scope of work
included the supply, manufacture and instal-
lation of a temporary works platform around
the 206-metre-circumference of the cooling
tower’s top rim.
The repairs (both internal and external to
the spalled concrete) and application of the
polyurethane coating to the rim were under-
taken from the purpose-built circumferential
platform during Sasol’s annual shut down
period of 12 days.
During the project a total of 8 m3 of
concrete was removed and repaired, 1,1 ton
of reinforcement was replaced and 220 m2 of
polyurethane coating was applied, following
which all access platforms and hoists
were removed. The project was completed
successfully within the programme’s time-
frame and without any safety incidents.
The group’s oil & gas service offering
extends across the South African borders,
and Stefanutti Stocks Civils KZN recently
completed its fourth project for Sasol Petro-
leum Mozambique Limitada. This entailed
the construction of access roads and five
well pads spread across the Temane and
Inhassoro gas fields, and located over a
50-kilometre distance from the central
processing plant (CPF) in Temane.
“We are proud of our long association
with Sasol, and that we have been able to
offer such a comprehensive skills set to
our client,” says Thompson. “We look for-
ward to continuing to build our relationship
with Sasol, both in South Africa and across
our borders.”
Polyurethane coating is applied to the top rim of
the cooling tower.
A view of the completed access
platforms running around the
circumference of the 165-metres
high cooling tower.
The Alimak hoist being erected along the side
of the cooling tower. This process took about
three weeks with commissioning.