Convoi has installed a new electricity generator for Mondi, an international packaging and paper group, at their plant in the north of the Czech Republic. Added complexities to this project were due to the factory layout being on several levels, and a significant difference in the size of the generator - which was twice the size and weight of the old one.
The Mondi plant in Štetí produces paper and packaging materials and boasts four Siemens generators producing electricity through heat generated during the production process. This energy is not only used for the companies own production process, but also sold on to a Czech energy supplier. The newly installed generator – which is significantly bigger and more efficient – replaces two old generators. Siemens’ regular transporter in the Czech Republic, Fracht FWO, called on Convoi to unload and install the generator. The assignment was carried out by Peter Holani, Project Manager Convoi Slovakia, in collaboration with Miloš Drahňák (Convoi Slovakia) and Martin Kokeš (Convoi Czech Republic). Undesirable situation Peter Holani described the project as one of the most challenging jobsyet, as a new platform had to be built to accommodate the size and weight of the new generator; ‘we went from level -1 to +7, and the fact that the production hall was packed with tanks, pump installations and pipes added greatly to the complexity’. Considering these factors, Mondi had initially anticipated the possibility of installing the generator through a hole in the roof – not an ideal solution considering the Štetí plant is decades’ old. Convoi has taken these challenges, and proposed a less time-consuming and more suitable, cost efficient solution. Distributing the pressure In finding a solution for moving the 103 tonne generator across the floor, the main challenge was that the floors were unable to support the weight of the generator and the 24 tonne weight of the lifting system which Convoi intended to use to move the generator internally.
With the designed solution, two out of four old generators kept running while Convoi was installing the new generator, resulting in little to no downtime.
Ultimately, Convoi designed a solution that allowed a more even distribution of the generators weight across the floor. “Jack plates were used to ensure the pressure of the generator was borne by the four corners instead of the centre of the platforms. In addition, the lifting beams of the lifting system had been extended from 18 to 20 meters to reach the necessary height. In the dodgiest parts we didn’t leave the generator on the lifting system but used the lifting beams to move it”, Holani explains. This solution meant that there was no need to move the generator through a hole in the roof – avoiding all ensuing consequences. Final result with the designed solution, two out of four old generators kept running while Convoi was installing the new generator, resulting in little to no downtime. Overall, Mondi was extremely appreciative of the service, as it saved them time, money and put less strain on their operations as they initially anticipated.