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Hydrocracking reactor for the
Novatek complex in Ust-Luga
WR Group transported a hydrocracking reactor and oversized equipment for Novatek complex in Ust-Luga
Year
2020
Cargo
Hydrocracking reactor + 10 additional
oversized equipment units
Dimensions Hydrocracking
Reactor
28.4 m length x 5.45 m width x
5.41 m height
Total cargo weight
~ 1.463 FR T
Route
Northern Italy - Ust-Luga, Russia

In December 2020, WR Group successfully handled an over dimensional cargo shipment on the Tuscany – Russian Baltic Coast route. This was a logistical project with several challenges given the prevailing world situation.

A hydrocracking reactor, heat exchangers, high-pressure separators, compressors and spare parts were transported to Ust-Luga for the reconstruction of the Novatek stable gas condensate fractionation and transshipment plant. In terms of dimensions, this project was one of the largest in Russia in 2020.

 

 

End operator of the equipment

 

Novatek is the largest independent natural gas producer in Russia. The Novatek complex in the commercial port of Ust-Luga on the Baltic Sea was commissioned in 2013 and processes stable gas condensate into light and heavy naphtha, paraffin, diesel fractions and fuel oil. In addition, the complex in Ust-Luga is used to process stable gas condensate for export. In 2019, construction of a hydrocracking facility for heavy residues (fuel oil) began at the industrial complex. The commissioning of the new plant will increase the processing depth and the production of higher value-added products.

 

Equipment for the processing complex was sourced from both domestic and foreign manufacturers. Some of the industrial equipment was purchased in Italy. WR Group specialists completely organised and implemented the transport logistics of the oversized cargo. As part of the delivery, WR Group also assisted the manufacturer with EAC certification.

WR Group’s project task

 

WR Group’s scope of services amounted to transportation of equipment from the production site to the port, control of the loading and unloading operations, consolidation of the equipment units at the port, organisation of a crane vessel, loading the vessel and shipping it to the port in Ust-Luga, loading and unloading operations on arrival, transportation of the equipment from the Ust-Luga commercial port to the Novatek’s production terminal.

 

In total, WR Group transported 11 oversized equipment units with a total weight of 620,000 kg. Including a hydrocracker reactor with dimensions of 28.4 m long x 5.45 m wide x 5.41 m high and weighing 280 tonnes.

 

 

Logistics

 

WR Group used self-propelled modular transporters to transport the large equipment from the production site to the shipping point in the Italian port and from the port in Ust-Luga to Novatek’s interim storage facility.

 

A challenge was for WR Group the lack of cranes to unload the vessel in the Russian port. Therefore, a crane ship was chartered for the shipment. The cargo left the port in Italy on December 3rd, 2020 and was underway for 19 days.

 

The special feature of unloading in the port of Ust-Luga was that the 280-tonne reactor had to be unloaded from the ship at a 16-metre distance from the edge of the mooring quay due to the limited carrying capacity of the quay. WR Group’s technical specialists and transport engineers developed a detailed unloading plan with precise calculations that took into account the characteristics of the crane vessel as well as the position of the cargo on the vessel and the specifics of the unloading location on the quay.

EAC certification

 

As part of the project, WR Group provided ЕАС certification services to the Italian equipment manufacturer. All equipment units were hydraulically tested in the presence of WR Group accredited certification experts. WR Group was able to organise the travel of inspectors and accredited experts to the manufacturer’s production site for conducting necessary tests on site, despite the movement restrictions due to the coronavirus.

 

WR Group managed to completely fulfil the client’s needs, thanks to its integrated solutions: the equipment, certified according to the requirements of the Technical Regulations of the Eurasian Economic Union, was transported across international borders with all safety measures, reaching the final operator within 19 days, meeting all delivery deadlines.