Focus on USAFocus on USAWood River and CCR ProjectWood River and CCR Project

Vessel LiftingVessel LiftingCroatia, Egypt, IndiaCroatia, Egypt, India

Double win!!Double win!!SC&RA and ESTASC&RA and ESTA

Issue 10Autumn 2009

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Three hundred modules, eighty barges,one hundred and twenty lifts and roadtransports: these are the impressivenumbers that make up this huge projectawarded to Fagioli Inc..

Fagioli was contracted to carry out therefurbishing and enlargement of one ofthe biggest refineries in Northern USA,which will provide 400,000 oil barrels perday. Even though the refinery is settled inIllinois, the project will involve the areasof the Gulf of Mexico, Europe andSoutheast Asia requiring Fagioli toinvolve a great amount of personnel andequipment.

The two main aspectsof the projects are theload-out operations onthe Mississippi riverand the logisticsactivities.

The Mississippi river (the third largestriver in the world) has an impressivewater flow. The load-out operations areperformed in an area where the river is800m wide; the weather conditions in this

region change drasticallyfrom hot summer to winterfrost passing through theflood and hurricane season.Also, all the unloadingoperations are executed inan area without a port andinfrastructure facilities. Thisis the main reason why wedesigned an in-house"mobile" quay (The Wedge)moved by SPMTs. Ourscope of work is to moveapproximately 40,000 tons of

oversized equipment.

The heaviest item is in excess of 1,000tons, the biggest one is 52m long, 20mwide and 16m high The modules areeither being loaded on barges by SPMTsat fabrication yards in the Gulf of Mexicoor arriving by ship. At the landing site theSPMTs roll-off and transport theequipment to the marshalling area builtbetween the river levees. Distance up to

Focus on USArefinery is 7 miles. This operation will berepeated for 100 barges and 300components.

The final installation of all these moduleswill be executed by crawler cranes (230tons to 660 tons capacity), hydraulicgantry system (350 tons to 550 tons) andspreader beams.

Logistic operations are very importantconsidering the huge amount of items tobe moved and the co-ordination of all theoperations involved such as the fasteningoperations on the barge, river transport,load-out, transport to the storage area,transport in the refinery to anotherstorage area, final movement toinstallation area within the premises andlifting! One of the most challengingaspects is that we are working in a liverefinery, there isn’t much room to positionthe transport and lifting equipment, plussafety and co-ordination with the workerswithin the refinery….These are all thingsto be considered!!

Fagioli is using its own specialisedpersonnel and also some local peopleafter being instructed with high-leveltraining courses organised by Fagioli.

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In December of 2008, Fagioli begandelivering items to support the CCR(Continuous Catalyst Regeneration)Project at a refinery in Pascagoula, MS.

The components included:(1) Splitter Column(2) Reactors(4) Convection Modules(8) UOP Modules, Upper / Lower Stack

sections(5) Substation Buildings.

Items were loaded onto barges by Fagioliand then offloaded at the jobsite. Theheaviest of the items was one of the UOPModules, at about 400 tons. Dimensions

of the components varied,with the largest being 25’wide, and about 36’ high. Allof the items were delivered to

an intermediate staging area within therefinery. Fagioli is now in the process ofmoving these items, and also additionalitems such as a Debutanizer andPackinox vessel, from the storage areato the crane hook at the final deliveryareas. At the peak of the project, Fagioli

will have 48 lines of SPMT’s on site. Theproject is anticipated to wrap up by theend of 2009.

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Vessel Lifting in Croatia

Fagioli carried out the lifting, tailing,traversing, rotation and placing of tworeactors at the I.N.A. Refinery in Croatiawithin a five day period – the first beingplaced on the 9th May, 2009 and thesecond on the 14th.

The first reactor to be lifted was the largerof the two at 41.3m long, 4.4m diameterand weighing 996 tons. Owing to siteconstraints, this reactor was delivered atabout 45 degrees to the lifting systemand offset from its’ foundation position.The reactor was lifted and simultaneouslytailed using SPMTs until it was vertical.At this point the tailing system wasremoved and the reactor traversed untilover its foundation.

In this position the reactor was rotatedand finally lowered into place. The liftingand tailing equipment was then re-located for the second reactor.

The second reactor was much smallerthan the first at only 19.6m long, 5.2mdiameter and weighing 511 tons, andtherefore the site constraints were less ofa problem. Again, this reactor requiredlifting, tailing, traversing, rotation andplacing.

The Fagioli Towerlift support structurewas used to support the strand jack liftingequipment. This arrangement spannedboth reactors, so relocation of steelworkwas not required between operations.

The details of the Towerlift configurationused on this project were as follows:

� Tower base stools fixed to reactor foundations to provide stability for thesystem.

� Twin towers, 53.1m high at 23m centres. Towers in standard 3.5m x 3.5m square format.

� Full tower top spreader arrangementsto ensure axial tower loads.

� Twin crosshead box beams fitted withskid rails and traversing equipment.

� Single jack support beams for tandemsupport of the two L600 lifting jacks. Beam provided with Hilman rollers forboth vertical load and side guidance.

The strand jacking equipment providedfor the lifting and traversing operations,was as follows:

� Two L600 lifting jacks each provided with a 37 part cable (s.w.l. 560 tons each). Lifting cables terminate in standard fixed anchors and trunnion type housings.

� Lifting jacks powered from an L4/35D power pack to give a lifting speed of 12metres per hour.

� Two L50 pulling jacks each provided with a 3 part cable (s.w.l 45 tons each)for each traversing direction.

� Pulling jacks operated from an L4/3D power pack to give a traversing speedof 10 metres per hour.

� All lifting and traversing operations controlled from a single remote stationat ground level.

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The rigging equipment for finalconnection to the reactors comprised ofthe following:

� A 1,700 tonnes capacity swivel, incorporating a low friction stainless steel / p.t.f.e. interface.

� The rotation of the reactors was achieved using Tirfor winches connected between the tower legs andthe reactor skirt.

� A final connection link and lifting pin fabricated to fit the reactor head lug.

The tailing arrangement comprised of thefollowing:

� Skirt beams designed to fit both reactors even though they had different diameters. These skirt beams are provided with two rocker pins which match up with saddles in the SPMT beams.

� SPMT beams fixed to the bed of the SPMTs to spread the load over the required length. These SPMT beamsare fitted with two saddles (front and back) to accept the skirt beam rocker

pins. The purpose of having two saddles is to ensure that before the centre of gravity of the reactor passesover the front saddle, the load is already in the back saddle and an overload or runaway condition cannotoccur. The distance between the saddles and the height of the second saddles are adjustable to suit the reactor diameter and centre of gravitylocation.

� For the first reactor, three 12 axle SPMT arrangements were provided and in this case the second saddles were mounted directly on the SPMT beams.

� For the second reactor, two 12 axle SPMT arrangements were provided. This shorter reactor required a spacerto be installed between the second saddles and the SPMT beams.

This was a very successful turnkey package for Fagioli in which we provided a complete service to the client, including all necessary supportworks (cranes, plant, labour, etc.) to ensure a safe, professional operation was carried out on time.

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Fagioli specialise in heavy transportationfor the shipyard industry involving thetransportation of boat sections and entireferry boats, as well as performing thelaunching of ships using the gears of itsgroup owned heavy-lift vessel. This kindof activity emphasises the competence ofFagioli engineering and our capabilities interms of equipment and know-how.

Our main priority is to perform all theoperations with contingency plans, pre-planned accurate method statements,specialised operators and state-of-the-artmodern equipment to assure thefundamental concept of a “Zero accident”philosophy. Safety first!!!

Fagioli was contracted to move andtransport a submarine at the port ofVictoria at Vancouver Island in BritishColumbia, Canada. This is not the firsttime Fagioli has transported a submarine.In 2005, Fagioli carried out a challengingtransportation and the positioning of the“Toti” submarine into the centre of Milan,which turned into an award for thehauling job of the year SC&RA contest(Specialised Carriers and RiggingAssociation) in 2006.

The operational displacement wasapproximately 2,400 tons.The scope of work required Fagioli toreceive the item from a Dockwise shipand perform the following activities:

� Loading of empty SPMT onto the ship� SPMT positioning under submarine

saddles� Loading phase by SPMT� Load-in on Victoria Ship-yard� Heavy transport at Victoria ship-yard� Final storage of submarine in refitting

area.

Fagioli had previously agreed withDockwise and Victoria port authorities,the loading plan/system and method ofload-in operations. Two 40 axle lines ofSPMTs, 3 Power Pack Units (PPU) and alink span bridge. All the operations weresuccessfully executed.

The three main techniques whenlaunching a ship from dry land to water,have been around for many years, evenwith all the technical advances thesethree techniques are still widely used:

The end-on launch, the oldest and mostfamiliar in which the vessel slides downan inclined slipway.

Another Submarinefor Fagioli....

Big Ships... Big Moves...

The side launch, which is still usedespecially for inland waters, rivers andlakes.

The float-off operation, used for thebigger ships built in basins or drydocks.

However, Fagioli used another techniquewhen launching a catamaran in Messina,in the wonderful island of Sicily, launchingby means of ...another ship!!!

Dimensions were 53m long, 15.5m wideand 13.7m high and weighing 280 tons.

Fagioli SPMTs were used to lift thecatamaran in a 2 x 10 axle lineconfiguration powered by two powerpacks. They were then moved onto thequay towards the self-geared group ownedStorman Asia ship. The heavy lift gearslifted the catamaran and carried out all thenecessary ballasting, allowing StormanAsia to move away from the quay andgently lower the catamaran into the water.

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Huge sections of a cruiseship were moved from Italyto Croatia using 136 axlelines of SPMTs, the firstsection weighed 3,233 tons.It was transported onto abarge in Porto Nogaro andloaded out onto a floatingdock in Croatia. The secondsection weighed 4,673 tonsand was loaded onto 192axle lines of SPMTs with 8power packs

Below the picture shows thelifting and moving of a 300ton yacht in Ancona from theclient’s premises to thelaunching area using ourSPMTs.

Another interesting operation was the one performed inMassa Carrara (Central Italy) for the transport of a 200 tonsyacht (45m long, 10m wide and 11.5m high). The picturesshow the huge boat being manouvered through the smallItalian streets.

Fagioli was contracted for thetransport and final installationof a huge bridge (see below) inFrassinoro, Italy. The bridge ofValdoria was built to allow safepassage of vehicles becauseof the frequent landslides thataffect the local roads. Thedimensions of the bridge areimpressive with a length of

160m, 15m wide and a maximum heightof 23m. The weight of the bridge isapproximately 820 tons. The bridge wasloaded by 48 axle lines of SPMTs andtransported 250m. Once in position it waslowered onto its final supports using theSPMTs hydraulic system.

Fagioli specialises in different activitiesfrom conceptual engineering to weighingand heavy transport of modules. Theweighing operation is a significant activityperformed by Fagioli. Various options forweighing can be used; SPMTs, FagioliJack’n Weigh Hydaulic System or FagioliWeigh Pack System.

Weighing by SPMTs is performed by liftingthe load onto SPMT hydraulics, thesehave calibrated high accuracy certifiedmanometers built in to the system. Oncethe load is supported by the SPMT, the oilpressure reading is taken and convertedinto kilonewtons by Fagioli software.

Fagioli recently performed the movementof a deck and jacket in Italy (picturesabove and below). 1 x 20 and 1 x 14 axlelines with 2 power packs were used tomove the deck and 2 x 8 and 2 x 6 axlelines with 4 power packs were used for thejacket. Both items needed to be weighedfirstly by SPMTs. The deck weighed 776.5tons and the jacket 505 tons. The SPMTswere fitted with calibrated digital pressuregauges. Weighing reports were issued tothe client including the calibrationcertificates. The weighing tolerances are ±3% and the centre of gravity location is ±1.5 % of the overall span of the SPMTshydraulic system.

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Fagioli carried out the transport of 4massive reactors from Italy to Poland.Two reactors weighing 809 tons each ,28m long, 7.5m wide and 6.30m highwere transported by a group-ownedbarge to Venice and directly loaded onto

For what concerns theKazakhstan area, Fagioli hasbeen executing severalinteresting projects for theoffshore industry. In 2008Fagioli was called to performthe skidding of modulesusing strand jacks, and in2009 the load-in by SPMTSof seven structural steelworkframes, weighing 738 tonseach with dimensionsof 35.7m long, 14.2mwide and 8.3m high.

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Fagioli was awarded the transport ofthree reactors (with a maximum weight of500 tons and a maximum length of 44m)from Italy to Spain. The turnkey projectstarted out in S. Giorgio di Nogaro wherethe reactors were loaded onto SPMTsand moved to Porto di Nogaro port. Thetranshipment was executed by a groupowned self-geared heavy lift ship toEscombreras port close to Cartagena,Spain. 32 axle lines of SPMTs were usedfor the final transport of the reactors aswell as the first part of the journey toPorto di Nogoro port.

Fagioli was contracted by one of thebiggest oil & gas contractors for thetransport and installation of more than200 items (columns, reactors, tanks,exchangers, turbine, compressors ...) foran LNG re-gasification plant in Soyo,Angola. Over recent years Fagioli hasgained a lot of experience with

a heavy lift ship by means ofvessel gears. The third wasloaded in Marina di Carraraweighing 1,068 tons, 29m long,7.5m wide and 7.3m high. Thetwo reactors arrived in Polandand due to the shallow draft,were transferred onto a localbarge with SPMTs. Fagioliperformed the load-in of the

reactors at the Deep Water terminal inGdansk. While performing the storageoperations of the two reactors, the thirdwas transported by barge to the refineryjetty where Fagioli carried out ro-rooperations and inland transport to a

storage area. The barge performed ashuttle-service to deliver the other tworeactors. The fourth reactor, the biggestone weighing 1,264 tons, 34m long, 7.5mwide and 7.3m high was loaded in MassaCarrara port after the transport frommanufacturing area with ro-ro operations.On arrival at the deep water terminal inGdansk, the reactor was transferred fromship to barge and transported to therefinery jetty. Fagioli then carried outload-in operations at the refinery jetty,and inland transport to the storage area.Barge mooring and ballasting operationsfor load-in/load-out activities were underFagioli responsibility.

transporting and installingitems/modules for LNG plantswith big projects such asSnohvit and Adriatic.

Some operations havealready been performed forthe project in Angola; theunloading operations andtransportation of the heavymodules by heavy transporttrailers and SPMTs.

In the next issue there will be a morein-depth report of the project,including images and text for theinstallation of the huge cold boxesand columns with weights up to1,150 tons!!

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Reaching the sky's........Fagioli Asia has been involved in theconstruction of two major projects inSingapore, the Marina Bay Sands andthe Pinnacle@Duxton. The Marina BaySands is a spectacular entertainmentcomplex located along the waterfront ofMarina Bay, featuring three cascadinghotel towers, topped with anextraordinary sky park, floating crystalpavilions, a lotus-inspired art-sciencemuseum, retail stores, restaurants,theatres, night clubs and casinos as wellas exhibition and convention centres,combining both business and leisure intoa singular destination. See picture below,an artists impression of what the complexwill look like.

Fagioli Asia were contracted to lift threelow roof structures. The two sections in

between the hotel towers were lifted intoposition without any problems, as thelifting points were located in each cornerof the roof sections. However, the 3rdroof section proved to be a verychallenging lift, it was 25 metres long andmore than half of its length wascantilevered out of the building. FourL100 strand jacks were used for the lift,,one pair on each side of the roof. Full

synchronisation of the jacks wererequired with the jacks spaced only twometres apart and lifting points close to thecentre of the roof made the roofextremely heavy one side, any nonsynchronisation of the jack would ofcaused the roof to flip over. Counterweights were placed at the other end ofthe roof in order to balance out the load.

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The Pinnacle@Duxton, is a residentialproject consisting of seven buildings. Allseven buildings are linked at the 26th and50th floors by sky bridges forming a joggingtrack and sky garden, a feature that isunique for public housing in Singapore.

This residential project when completed,holds two world records for the longestsky-garden and the heaviest sky-bridge,weighing 354 tons. The lifting of the 12sky-bridges was awarded to Fagioli Asiaby TTJ Design & Engineering Pte Ltd.

Each sky-bridge was lifted using four ofour versatile L100 strand jacks along withtwo electric / hydraulic power packs. Asthe length of strand cable is 150m long,recoilers were used to store the strand tofacilitate relocation to the next liftingposition.

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“Almajdouie PSC, a Joint Venture ofAlmajdouie and Fagioli, specialise in themulti-modal transportation and lifting ofheavy and oversized cargo, chiefly in theMiddle East region. Based in Bahrain,with regional facilities in Dammam, AbuDhabi and Kuwait, over the last fewyears the company has established aleading position for carrying out complexengineered projects. Recent highlightsinclude:

12km inland transportation andinstallation of nine units of 1,800 tonevaporators to the Marafiq IWPP projectin KSA. The cargo had to be partlytransported through a residential areaand involved the complete design of thetransport system door to door, includingbridge strengthening, utilities plan,environmental plan, permissions etc.

160km inland transportation, possibly thelongest distance ever in the Middle Eastusing self propelled transporters, fromJubail to Maaden in KSAof a CO2 absorberweighing 518 tons, andan HP flash vessel at413 tons. The cargo wastransported over thislong distance safely andquickly, and at times intemperatures of over 40degrees centigrade.

With projects like these achieved on time,on budget and safely, Almajdouie PSChas enjoyed a period of rapid expansionin areas all over the Middle East, and agrowing reputation for quality and

innovation. This hasculminated in the recentaward of three majorprojects:

Al Dur IWP Project,Bahrain – Almajdouie PSCis has been contracted byHyundai Heavy Industriesfor the inland ProjectLogistics of approximately250,000 freight tons ofgeneral, heavy andoversized cargo, includingmulti-modal receiving atthe Khalifa Bin Salman Portand delivery to site by selfpropelled, conventionaland lowbed trailers, and100 items up to 250 tons byBarge and RoRo.

Shuweihat S2 IWP Project,UAE – Almajdouie PSC,

has been awarded two contracts byHyupjin Shipping on the new phase ofthis desalination and power projectlocated in the Emirate of Abu Dhabi. Thefirst is the ro-ro, inland transport anddelivery onto foundation of six 3,800 tonevaporator units that are more than 100metres long. This project has recentlybegun and two units have already beendelivered.

The second contract is for thetransportation of major power plantcomponents, HRSG’s and transformersup to 300 tons. Fagioli is required toreceive the components from Mina ZayedPort, roll on, transport by barge, roll offand deliver to site.

The company has this year expandedrapidly to meet the requirements of theseprojects, and in expectation of the majorprojects in the petrochemical and powersectors that will be built in the next fewyears in the region.

The Middle East

Between the delivery ofthese items and theinstallation, the client hadassembled two of thesections on site to form a52m high deethanizer.The remaining foursections formed the huge95m high Splitter. Thevessels were assembledand dressed withinsulation, platforms andladders.

Then in July 2009 thedeethanizer (7m wide, weighing 600tons) was lifted using our tower lift andstrand jacking system. Tailing wascarried out using a tailing frameconnected to the vessel and attached to2 x 12 axle lines of SPMTs.

In August 2009 Fagioli then performedthe final installation of agigantic Splitter withdimensions of 92m high;

9.2m wide andweighing 1,050 tons.Fagioli used a 113mhigh tower lift systemwith strand jacks.The tailing operationwas carried out byFagioli’s brand newLR 1750 crawlercrane. Once theSplitter was lifted, itwas moved acrossthe top of the liftingbeam using rollersand L50 puling jacksthen positioned ontoits 9m high plinth.

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During July and August 2009, Fagioli wascalled to lift and position two vessels (asplitter and a deethanizer stripper) for theEgyptian Polypropylene Complex project.

The six items which made up the splitterand deethanizer stripper had alreadybeen transported at the end of 2008 fromKorea to Egypt, unloaded at Port Saidand transported to the complex. Thiswas mentioned in our last news letter.

EgyptNot quite the pyramids but stillimpressive !!

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There are many aspects to be consideredbefore handling a heavy transport,especially when dealing with turn-keyprojects. Solutions proposed are alwayshiding some unexpected contingenciesthat need to be planned and overcome.This is the main reason why Fagioli putstechnology, innovation and engineeringfirst.

Fagioli performed an interesting turnkeyproject recently for the transport and finalinstallation of an 18V50 engine fromTrieste to Osoppo (UD) in the North-Eastpart of Italy.

The engine was loaded in Trieste ontoour group-owned vessel `Storm`. Theself-geared heavy lift motor vesselheaded to Nogaro port and unloaded theengine directly onto two 12 axle linemodular trailers with shoulders pushedby two prime movers. The engine wasthen transported 60km to the client’spremises. The journey proved to be quitedifficult, not only were the roads uneven,but in some areas extremely narrow.Once the engine had reached itsdestination, it was transferred onto amore suitable trailer. The final installation

Overland Heavy TransportFagioli provide turnkey projects allaround the world. An example is theFeriana project in Tunisia. Fagioli carriedout the transport and final installation ofthe following items for a power plant:

Fagioli performed the following activities:

� Receiving the items from the heavy liftship and loading onto Fagioli trailers inGabes Port;

� Inland transport from Gabes Port to Feriana Power Plant;

� Offloading (skidding system) cargoes on foundation;

When carrying out door to door projectslike this, there are several factors thatneed to be considered; the condition ofthe roads; the distance; the weather; andany obstuctions. The route for thisproject required Fagioli to pass through ahistorical arch in the town of Gafsa. Thetransversal transport beamspositioned under the Gasturbine were removed, toallow the convoy through, andthen reinstalled to the originalconfiguration to proceed to itsfinal destination. Once the

No. Item Weight (te)1 Gas Turbine 208 1 Generator 2001 Modules Auxiliaries 541 Transformer 107

was performed with Fagioli EZ600 gantrylifting system.

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Dimensions LWH11.35 x 5.80 x 5.80m 9.74 x 4.31 x 5.63m8.4 x 3.65 x 4.15m7.18 x 3.48 x 4.48m

convoy trailer had reached itsdestination, the generatorwas transferred onto a short11 axle trailer by a screw jacklifting system. The gasturbine was temporarilystored on stools then loadedonto a 11 axle trailer by thetrailer lifting system. Trackswere laid out and rollers werepositioned onto the tracks.The generator and gasturbine were skidded to theirfoundations. The finalpositioning was performedwith hydraulic jacks!

Here the picture shows an 80 ton turbinebottom structure being moved fromLegnano (Italy) to Brema (Germany). Thewidth of this item was approximately6.2m.

The transportation of a cryogenic tankwas performed in Genova by Fagioli, withthe use of a 16 axle line lowered trailer.The tank had a diameter of 4.1m, 24mlong and a weight of 42 tons. The finaldestination was Castelnuovo del Garda,but the most challenging part wasmanoeuvring the tank through the narrowstreets of Genova.

Another huge project in terms of weightand length of the convoy, was thetransport of a bottom base structure for agigantic press from Terno d’Isola toCividate Camuno in Italy. The basestructure weighed 500 tons and wasmoved by two prime movers and two 11axle line SPMTs with a Schnabelstructure. The total convoy was 70m inlength.

Overland transport for us is a dailyroutine like brushing your teeth!!

A project carried out successfully thanks to thedetermination of our permit department, was thetransportation of several cold boxes, originatedfrom China and destined to Castelnuovo del Garda(VR) in the Northern East of Italy. The items wereloaded onto our group-owned barge anddischarged in Mantova where they were positionedonto Fagioli trailers for the final transport. Theheight of the cold boxes was 7.3 metres, and assuch over 100 telephone cables had to be lifted toallow passage of the convoy. As well as this, theroute through one of the towns was initially denied,however after long discussions and manymeetings, Fagioli managed to persuade them byreinforcing the roads with steel plates.

Another project that required the removal ofobstacles, was the transportation of a 275 tonexchanger module and a 42m long column fromthe manufacturer in Ornago across the NorthernItalian territory to Cremona river port. The columnwas 7.5m high and as such Fagioli had toremove posts, traffic lights and electrical cablesto allow the convoy to go through.

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Fagioli India were contracted to lift fourlarge DHDT reactors for two differentrefineries in India.

The first project was carried out in March2009 for the Bongaigaon refinery, Assam.An extension project for one of India’soldest refineries. It was on this project,that Engineers India Ltd, reputedGovernment recognised engineeringconsultants for the refinery sector,approved for the first time, the use ofstrand jacks to erect the reactors. Thecontract was awarded to Fagioli India byStewarts and Lloyds of India Ltd whowere the appointed erection contractorfor the DHDT unit.

The first vessel was 31 metres high andweighed 422 tons. The second reactor33 metres high and weighed 496 tons.

They were erected using the Fagiolitowerlift system which consisted of a pairof rectangular 3m x 3m section towers, 36metres high and spanning 15.9 metres bytwo crosshead beams 18.6 metres wide.

On top of the crosshead beam was asingle L600 strand jacks powered by aL/35D-2 hydraulic power pack.

Connection to the reactor was with aspecially designed link plate assembly toaccommodate the reactor lugs and aL600 anchor housing. An additionalswivel assembly was introduced tofacilitate rotation of the reactor, beforefinal placement of the reactors on to itsfoundation. Tailend of the reactor wasshifted and tracked by a 450 ton capacitytailing crane untill the reactor wasvertically aligned

The lifting operation took approximately3.5 hours at a lifting speed of 12m/hour.

Once the lift was completed, thesuspended reactor was held in positionfor 1.5 hours while the skirt was alignedbefore it was finally lowered and restedon to its foundation.

The second project was performed inApril 2009 in co-operation with Petron

Vessel Lifting in IndiaEngineering Construction Ltd to erect twoheavy reactors for IOCL VadodaraRefinery DHDT project.

The first vessel R-02 was 31 metres high,and weighed (including dressing) 791

tons. The secondreactor R-01 was 28metres high andweighed (includingdressing) 688 tons.They were erected in asimilar arrangement asthe reactors atBongaigaon refinery,using the Fagiolitowerlift system, except

they were a pair of rectangular 3m x 2msection towers, 36 metres high with acrosshead beam spanning 25 metres.The beams were specially designed andfabricated to achieve the span andrequired lifting capacity. On top of thecrossheads were a pair of L600 strandjacks powered by a L2/70D hydraulicpower pack. To avoid using a highcapacity crane for the tailing, Fagioli Indiadesigned and fabricated a tailing frame(see photo below). The frame consistedof a base frame mounted on rollers. It

was connected to the skirt of the reactorwith a pin connection. The pin connectionallows the equipment to rotate at thatpoint during lifting. Connection to thereactor was with a specially designed linkplate assembly to accommodate thereactor lugs and L600 anchor housing.

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As well as our high capacity liftingequipment such as strand jacks andtowerlifts, Fagioli own a large range ofmedium capacity lifting equipment ideallysuitable for heavy assembly such asScrew Jacks and Gantries.

These were used in the transportationand temporary installation of a 170 tonstator (pictured above and below) fromSesto S. Giovanni to Sarmato in thenorthern part of Italy.

The stator was commissioned to the clientfor the refurbishing of a steam power plantwhich previously generated energy topower a sugar manufacturer which is nowclosed. The steam power plant now

produces energy to be sold on the market.The stator was loaded onto a 16 axle linemodular trailer and moved approximately80km. The item was than unloaded andpositioned in a storage area within thepremises. The unloading procedure wasperformed with Fagioli versatile screwjacks system, very simple and efficientlifting device particularly useful inrestricted areas. The heavy duty screwjacks are mechanical linear actuators ableto lift up to 600 tons (4 units) used to load

and offload items. As thejacking units can beconnected by spreaderbeams, Fagioli prepareda structure to facilitate

the movement of the load from the trailersdirectly onto the concrete supports withinthe storage area.

The gantry crane system is a mobile, self-propelled lifting device intended to beoperated on steel plates or tracks. Thisequipment can be shipped anywhere inthe world. One of the most recentinstallations performed with a gantrylifting system was a project in Syria.

Fagioli was contracted for the transportand installation of two gas turbines andtwo generators for the new gas plant inBanias. The two gas turbines originatedfrom Italy and were transported fromTurin to Marghera port with group ownedtrailers. The turbines weighing 210 tons,

Heavy Assembly !!The Answer is... Screw Jacks and Gantry Systems

with a diameter up to 4.7m werepositioned onto 2 x 11 axle line trailerswith a Schnabel structure as support.Once they had arrived at the Venice port,the items were loaded onto the Storm

vessel, a companyowned heavy lift ship,then transported by seaand unloaded at Tartus.A local forwarder wascontracted by Fagioli forthe inland transport fromTartus to Banias. Oncethey had arrived at thedestination, a Fagioli

gantry lifting system was used to installthe turbines onto their foundations.

The two generators (weighing 210 tons)originated in England, arrived in Tartus(Syria) and were transported to Banias andfinally positioned onto foundations with thesame gantry crane used for the turbines.

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Like other industries, project logistics andfreight forwarding have been sufferingfrom the global decline that has beenaffecting most organisations around theworld. Luckily, the contracts awarded toFagioli in 2008, have been enough tocarry us through this terrible periodwithout suffering too much. However, webelieve that our field of activity willexperience a slowdown in 2010, a naturalconsequence from the lack of jobs fromour main clients.

We are currently carrying out severalprojects in Algeria, U.A.E. and SaudiArabia and coming to the end of somehuge projects in India, however, we areconfident that we will be offered furtherplant installation for the oil and gasindustry in this region.

The Middle East is proving to be one ofour most significant markets mainly dueto our clients, the large EPC contractorsinvesting in these flourishing countries.UAE, in particular, hasseveral important Oil &Gas projects whichprovide a third of thecountry’s gross nationalproduct. Fagioli havebeen involved in theinitial stages of some ofthese projects offeringtechnical andeconomical advice.

Over the last few yearsFagioli has seen aradical change in theway petrochemicalplants are built. Theincreasing pressures toconstruct plants withinbudget and tighterschedules, has meantthat organisations havehad to become more

inventive. One of the new ways ofconstructing is through modularisation,pre-assembling modules including pipes,cables and supporting structures atground level in the fabrication yards andthen transporting them to their finaldestination where they are connected toform part of the entire structure.

This new approach requires newtechnologies and with the modulesbecoming bigger and bigger, stringentengineering studies need to beconducted so that safety and quality arenot compromised.

Technology, reliability and innovation arethe key words!!!

Thirty-seven packages destined to Qatarwere transported from Lonate Ceppino toCremona river port. The material (withitems up to 97 tons) was loaded ontoFagioli trailers, moved and transhippedonto barges in Cremona (by means of agantry system) and headed to Venice.

Fagioli loaded twocolumns in Naplesdestined to Mersina,Turkey with finaldestination to Iraq. Thecolumns are 25.9m and27m long with amaximum weight ofapproximately 21 tons.

A big applause goes to the team involvedin the forwarding of Humanitarian aid fora continuous successful service. Fagiolioperates all over the world wherever aidis required and in places where there arelogistical difficulties, and inadequate localstructures unable to support the incomingof cargo. In some cases, our operatorshad to personally go to these countries toverify the capacityand reliability oflocal operators tomake sure a highlevel of service isprovided.

Although Europe isnot our mainmarket for projectlogistics, we arecurrently workingfor an important

Project Logistics

In North Africa the combination offorwarding, heavy transport and liftingactivities continues to be a great success,particularly in Algeria where there hasbeen many opportunities in the oil & gassector which has led to Fagioli setting upa branch in Oran, made up of a team ofexpatriates and locals.

In Libya we are completing the transportand final installation of modules andboilers for the local Libyan Authority forthe Energy in Zawia, with the use ofgroup owned equipment and personnel.

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Italian client for the completion of a bio-diesel plant in Rotterdam.

It includes the transportation of two 900ton reactors (see picture below) for whichwe used our internal resources. Theproject covers a total of approximately60,000 freight units with materialoriginated from Europe and the Far East.

Fagioli has been awarded for thetransport contract of 4 power plantsdestined to Greece, Italy, Belgium andFrance. The items originate from Korea.The total in freight tons is approximately70,000, 60 modules in total with amaximum weight of up to 200 tons.

Other forwarding activities involve thecontainer transport of material for theconstruction of a hotel in Martinique.Plus, Fagioli has been awarded a hugecontract in North-Africa… we will reportthis in the next issue!!!

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One of our “newest” departments set-upin July 2005 is becoming a significant unitfor all the other departments within thecompany!! Following the Fagioliphilosophy F.I.S. (Fagioli IntegratedSystem), all our departments areindependent but linked in order to provideour clients with a top-level turnkeyservice. This is the case of the Milanbased Airfreight department. In ourNewsletter 07, we mentioned about theincrease of work performed by the

Airfreight

The Flight of the Airfreight Department!!

Fagioli has alwaysbeen in the forefront ofshipping when itcomes to theaerospace industry,such delicate materialrequires special careand expertise. Tworecent projects both

department, not only assupport to the projectlogistics department, butalso the commercialdivision. During theselast months, we haveseen great performancesin terms of cargo tonnageforwarded. In order tocontinue the Fagiolitradition “specialising inmoving oversize items”

the airfreight department is often called toload over-dimensioned pieces in terms oflength, width and height as well asweight. As a matter of fact Fagioli recentlyperformed the shipment of two pumps(5.41m x 2.88m x 2.65m, 13 ton each)from Italy to Abu Dhabi. In Italy Fagioliused group owned equipment for theroad transport, then transhipment on toaircraft and then final transportation tosite using a qualified local subcontractor.

destined to Korea,one was for thetransportation ofsatellites loaded inItaly with group-owned equipment,road transported toAmsterdam airportand flown to USA.

The second wasperformed inMalpensa for the shipment of satellite sections and accessories stowed

in containers.

The airfreight department regularlyoperates with the main international aircarriers, handling items frommanufacturing sites to final destinations,anywhere in the world. Fagioli weredelighted to receive the certificate ofappreciation for the “continued supportduring 2008/2009” from one of the mostimportant airfreight carriers in the world!

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Heavy Rail TransportFagioli is aware of the importance toperform a quality door-to-doorservice. Our extensive fleet ofequipment strategically based aroundthe world, enables us to perform anyfeasible transportation and liftingactivity imaginable anywhere in theworld. This and the combinedexpertise and experience of thedifferent departments within ourorganisation, is the key to asuccessful door to door service andthis was certainly shown on thetransportation of a 160 ton trafowhich originated as a road transportfrom Legnano to Busto Arsizio, inNorthern Italy.

The flexibility of the trailers allowed theload to be transported close to the railtracks. After a change in trailerconfiguration, the trafo was lifted with agroup owned gantry lifting system andpositioned onto the rail cars.

The heavy rail transport started in BustoArsizio and ended in Tirano (a beautifultown positioned very close to the Swissborder) where the trafo was re-loadedonto the trailers and moved up to its finaldestination (a power station).

One of the important aspects of heavyrail transport is avoiding obstacles liketree branches or fallen rocks, extracare needs to be taken to assure theroute is clear.

The rail cars are extremely versatile.There are many tailor-madeconfigurations that can be created,depending on size, weight andstructure of the load.

With a large range of rail cars (up to32 axle line wagons with a capacityup to 500 tons), Fagioli are able tochoose the most suitableconfiguration as well as auxiliaryequipment and any special structuresneeded for the transport. Schnabel

structures either with shoulders orplatforms; “cage” structures to closeand support the whole item;supporting “split beam” are alldifferent configurations used todisplace the weight of the item andallow the transport on tracks.

The heavy rail transport departmentwas established in 1969, since then ithas adapted to new and challengingrequirements of the market. Theexperience Fagioli has is an importantfactor when dealing with peculiar jobslike this!!!

The small picture shows the railtransport of a huge generatorweighing more than 400 tons with thetypical “cage structure”

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A Double Win for

Fagioli!!

ESTA is the European Associationfor heavy haulage, transport andmobile cranes. Once a year theyhold an awards ceremony torecognise the achievements ofcompanies in two catergories,each for lifting and transportationprojects, plus safety and otherawards. Fagioli won the awardfor the transportation of bridgesections in the catergory foroperations with more than 120tons gross vehicle weight.

It’s a Winning Year for Fagioli at the ESTA and SC&RA Awards...

Fabio Belli, our Managing Directorpicked up the award on behalf ofFagioli at the awards dinner held on23rd April in Paris. (see photo bottomleft). The event was attended by morethan 470 people.

Fagioli also celebrated the SC&RAjob of the year award. This is the thirdtime Fagioli have won such an award.This year we won it for the Adriaticproject, an LNG receiving and re-gasification terminal installed in theAdriatic sea (see picture below).

This project fell into the catergory ofrigging job more than $750,000.

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The Rigging Job of the YearCompetition is designed to honourand give special recognition tomembers that perform outstandingachievements in solving problemsencountered in rigging. EdoardoAscione, General Manager of FagioliInc. had the pleasure of picking up theaward for Fagioli. (see picture above).

Contributions & Comments

Thank you to all those who contributed to this edition of the News Letter. We appreciate your comments please continue to send them to either of the personsnamed below:

Nicola Mowatt Rudy CorbettaFagioli Limited Fagioli S.p.A

The Ridgeway, Iver Via Vigentina 2, Bucks, SL0 9JE, UK 20090 OPERA, Italy

Tel: +44 1753 659000 Tel: +39 02 576901Fax: +44 1753 655998 Fax: +39 02 57690454n.mowatt@fagioli.com r.corbetta@fagioli.com

Visit our website at www.Fagioligroup.com

“The one who stops in life, is lost” is notonly a typical Italian saying but also theFagioli way of thinking.

A completely redesigned and enhancedwebsite has been launched by ourcreative IT department: time and marketrequests are changing faster and fasterand Fagioli does not want to stay behindthe times!!

With a totally fresh look and format, thenew website contains more information

Fagioli World

Abu Dhabi (U.A.E.), Algiers (Algeria), Atyrau (Kazakhstan), Bejing (China), Bierun (Poland), Calgary (Canada), Dammam (Kingdom

of Saudi Arabia), Durres (Albania), Essen (Germany), Hong Kong (China), Houston (USA), Istanbul (Turkey), London (UK), Mumbai

(India), Oran, (Algeria), Paris (France), Perth (Australia), Seoul (Korea), Singapore (Singapore), Tehran (Iran), Tripoli (Libya), Tubli

(Bahrain), Tunis (Tunisia).

New Fagioli Group Website

on all the advancedservices provided byFagioli. The new websitehas been carefullyredefined to make iteasier for everyone tofind information andinteract with it. Thewebsite contains manyfeatures such as thelatest company news,

Exhibitions

Fagioli participated with a stand at thefirst exhibition dedicated to cranes inItaly. The exhibition called “GiornateItaliane del Sollevamento” was held fromthe 11th to the 13th of June 2009 inPiacenza. This gave Fagioli theopportunity to present the “Adriatic LNGProject”. A presentation given by Mr.Ferrari and Mr. Ronchini.

Pushing the Lifting Limits Beyond ...

On 16th of October 2009 Fagioli wasproud to present at Liebherr premises, itsnew huge LR 11350 crawler crane, an

outstanding machine with a capacity ofup to 1,350 tons! More information willbe available in the next issue!!

improved usability and navigation, newvideo gallery of some amazingoperations, improved photo gallery, andeasy-access to downloads ofnewsletters and brochures.

We have tried to make the website assimple and clear as possible. I hope wehave managed to do this!! Feel free tomake any comments and drop a mail tothe marketing department!!