Mammoet Completes Coke Drum Integrity Upgrade Ahead of Schedule in Canada’s Oil Sands

30 Second Takeaway

Mammoet has successfully supported a major coke drum integrity upgrade at a large Canadian oil sands mining operation in Fort McMurray, Alberta, completing the replacement of eight coke drums ahead of schedule. Early involvement, detailed planning, and the strategic use of heavy lifting and transport solutions proved critical in reducing shutdown time and extending the life of the upgrader by an estimated 30 years.

Coke Drum Replacement Scope

Supporting a Critical Upgrader Process

The oil sands upgrader uses thermal and chemical processes, including coking and hydrotreating, to convert bitumen into synthetic crude oil. During this refining process, coke drums collect petroleum coke separated from the feedstock, making them essential components within the facility.

Each coke drum weighed approximately 270 tonnes and measured 7.9 metres in diameter and 29.8 metres in height. Positioning components of this size required one of the world’s largest cranes and a carefully engineered lifting strategy.

Heavy Lift Engineering and Crane Selection

Reach as the Deciding Factor

Mammoet conducted extensive feasibility and crane selection studies for the project. Rather than lifting capacity alone, crane reach was identified as the critical factor, enabling the replacement work to proceed without interrupting other concurrent maintenance activities across the site.

The team selected the PTC210DS ring crane, which allowed lifts to be performed from a greater distance. Because the crane was installed inside the coke pit, significant civil works were required, including the installation of approximately 200 piles to create a stable foundation for the crane.

Transport and On-Site Execution

SPMTs Enable Continuous Progress

New coke drum components were delivered well in advance from Edmonton to Fort McMurray. Once on site, Mammoet used self-propelled modular transporters (SPMTs) to position the components efficiently.

Two SPMT sets operating day and night enabled continuous progress, helping to accelerate turnaround execution. Mammoet also fabricated specialized rigging and adjusted crane configurations when one component was found to be heavier than initially estimated, ensuring the project remained on schedule despite changing conditions.

About Mammoet

Mammoet is a global leader in engineered heavy lifting and transport services, supporting the construction, maintenance, and decommissioning of large-scale infrastructure and industrial projects worldwide. With more than two centuries of combined experience, Mammoet specializes in moving and installing the largest and heaviest objects on earth.

In Canada’s oil sands, Mammoet has been an active partner since 1967, providing heavy lift engineering, crane services, and transport solutions that help operators execute complex shutdowns, turnarounds, and capital projects safely and efficiently.

Website: https://www.mammoet.com

Frequently Asked Questions

What was the scope of Mammoet’s work in Fort McMurray?

Mammoet supported the replacement of eight coke drums at a large oil sands upgrader, including feasibility studies, crane selection, heavy lifting, transport using SPMTs, and on-site execution support.

Why was early planning important for this project?

Early planning allowed Mammoet to develop the optimal lifting and transport strategy, minimize shutdown duration, and coordinate work alongside other site maintenance activities.

Which crane was used for the coke drum installation?

The project utilized Mammoet’s PTC210DS ring crane, selected primarily for its reach, allowing lifts to be executed without disrupting other operations.

How were the coke drums transported on site?

The coke drums were moved on site using self-propelled modular transporters, with two SPMT sets operating continuously to maintain progress and support an accelerated turnaround schedule.

What long-term benefit does the upgrade provide?

The coke drum replacement is expected to extend the operational life of the upgrader by approximately 30 years.