Construction World October 2016

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.

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 m 3 of concrete was removed and repaired, 1,1 ton

of reinforcement was replaced and 220 m 2 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.”

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Polyurethane coating is applied to the top rim of the cooling tower.

CONSTRUCTION WORLD OCTOBER 2016