A 350 tonnes generator from the Ibbenbüren power plant, which has already been shut down, is to be transported to the active Niederaussem power plant as a reserve generator. At the same time, the defective generator at the Niederaussem power station is to be moved to a different position.
Our task initially consisted of preparing the feasibility study and transporting both generators to Niederaussem and then positioning them within the power station.
After detailed CAD simulations, route tests, static calculations, method statements, risk assessments, etc. as well as multiple coordination meetings on site with representatives of the authorities and stakeholders, which took around 6 months, the transport could be realised.
The lack of generator end plates for this type of generator and the resulting overall dimensions of the transport variants made the project a particular challenge for man and machine.
Experience of transport operations of this size suggested some challenges. Nevertheless, this transport was a logistical masterpiece.
As the distance of 200km, transport dimensions of up to 105m x 6.3m x 5.7m (LxWxH) and a weight of up to 798 tonnes could not be transported by road alone, partly because of the Rhine that had to be crossed, this project required multimodal transport in 5 variants, with reloading, lifting frame, lifting portal and bridge crossing inserts, etc.
In 6 months of preparatory work, different variants of the routing, parking and conversion options were determined. Our concept, including crossing times of the A57 motorway, was approved in multiple consultations with the police, representatives of the authorities and traffic safety officers.
The axle load of 14 tonnes specified in the bridge calculations could only be achieved with a combination of the high girder bridge G² I K600 with 2×26 axles and a weight of up to 798 tonnes.
A 20-axle SPMT with two Powerpacks was used for the first stage, 10 kilometres from the Ibbenbüren power station to the nearby port. Loading was carried out using the vehicle’s own hydraulics. With overall dimensions of 34.6m x 4.4m x 5.8m (LxWxH) and a weight of 470 tonnes, the generator was set in motion.
With an overall length of 34.6m, the tight space conditions and curve radii in the power station as well as the power station exits and harbour entrances made the use of this extremely manoeuvrable self-propelled combination indispensable.
Due to a weak structure on the route, we also used our bridge overpass system with a total length of 32 metres, preceded by various coordination meetings for implementation. For the installation on the public road, one side of the road had to be closed with additional traffic lights.
The use of the SPMT with the increased axle loads on this section of road was authorised without the need to drive over any other bridge structures during the run-up. In the harbour, the SPMT was rolled onto the drive-in pontoon provided for water transport from Ibbenbüren to the Cologne-Langel ferry ramp without any problems.
As no end plates were available for this type of generator to support the load, the reloading in Cologne-Langel was a masterly feat of assembly. First of all, the transport frame in which the Geno was located during the SPMT transport had to be dismantled in order to be able to pass under the bridges that had to be crossed further along the route.
It was not possible to park the Geno and pick it up hydraulically; the use of a lifting frame was essential. The 10-12% gradient of the ferry ramp made things even more difficult.
To ensure the optimal and safe use of the 1440t lifting capacity mast we were commissioned with, the ferry ramp and transfer area were prepared with temporary foundations and erected in one day. Pre-assembly and positioning of the high girder bridge G² I K600 took place beforehand.
After the roll-off with a 10-12% gradient, the Geno was lifted using the lifting frame and hoisted into the load suspension of the high girder bridge G² I K600 .
Due to the specified maximum axle loads of 14 tonnes for the bridges to be crossed, the high girder bridge G² I K600 was carried out in various variants with a 2×16 axle combination and the bridge crossings were monitored by bridge monitoring.
After arriving at the inspection car park of the Niederaussem power station, the Geno was set down on its load suspension and elephant feet using the hydraulic lift of the high girder bridge G² I K600 and the boiler bridge was dismantled around it so that it could be hydraulically picked up again by a 20-axle self-propelled transporter combination provided and then transported to its destination within the power station.
The defective generator located in the power station was previously loaded using a lifting frame and moved to the same location as the reserve generator.
The challenge of this transport was to find a suitable route with a total weight of up to 798 tonnes and dimensions of up to 105m x 6.3m x 5.7m (LxWxH). Only the unique design of the high girder bridge G² I K600 meant that this transport could be carried out safely and within the specified axle loads at all times on the 200 km route with roundabouts and bridge structures. Conversion work on the route in a total of five vehicle variants, including a bridge crossing combination with monitoring, was necessary due to the specified axle loads with the required axle load reductions and the route conditions. The guarantee of traffic safety, compliance with working time guidelines and occupational health and safety for man and machine had to be ensured at all times within the legal and responsible framework.
