Reactor replacement
Client: Breetec
Project owner: Tessenderlo Kerley
More info: [email protected]
In 2024, we assisted our customer Breetec in replacing a 120-tonne reactor at the Tessenderlo Kerley plant. The replacement took place during a planned shutdown, making it crucial to ensure that all critical connections were precisely re-installed in their original positions.
Works performed:
- Laser scan of the existing situation
- Measurement of critical connections on the existing and new reactor
- Measurement of anchor holes at the bottom of the existing and new reactor for replacement in exactly the same place
- Transferring the anchor holes onto the new steel beams
- Topographical measurement of the new reactor with the total station
- Real-time alignment of the new reactor using the total station
The reactor was mounted on steel beams which were also replaced as part of the project. To ensure precision, we meticulously transferred the anchor holes of the new reactor onto the new steel beams. This process began by projecting the measurements of the existing reactor onto the current setup, ensuring the critical flanges were positioned perfectly. Next, we measured the new beams and aligned them with the supporting columns of the old beams. Once the anchor holes were marked on the new beams, they were pre-assembled with the new reactor.
During installation, the alignment of various projections and measurements was put to the test. The anchor holes aligned flawlessly, and the critical connections were positioned with milimeter-level precision.
CISS also performed real-time alignment of the reactor, measuring the verticality and positioning of critical connections immediately after installation. Any necessary adjustments were promptly communicated to the customer. By the end of the process, the new reactor was well within all specified tolerances - a project we are incredibly proud to have accomplished.
