Sarens Completes High-Risk K101 Installation at Orlen Lietuva Refinery

30 Second Takeaway

Sarens has completed its first full-scope heavy lifting and transport project in Lithuania with the successful installation of the 40-metre-high K101 unit at the Orlen Lietuva refinery, demonstrating precision engineering and meticulous execution in a narrow, high-risk operating environment.

Sarens K101 Installation Orlen Lietuva Refinery Lithuania

Sarens has successfully completed the installation of the K101 deep oil refining unit at the Orlen Lietuva refinery in Lithuania, marking the company’s first-ever full-scope heavy lifting and transport operation in the country.

Commissioned by Petrofac, the project required Sarens to deliver an integrated scope covering engineering design, equipment supply, transport, and installation, executed within one of the refinery’s most technically challenging operational zones.

Extreme Constraints Inside an Operating Refinery

The central challenge of the project was the installation of the 40-metre-high, 100-tonne K101 unit in the middle of an active refinery.

The work environment presented exceptional constraints:

• Extremely confined spaces, with clearances measured in tens of centimetres

• Live equipment operating in close proximity

• A high-risk, hazardous atmosphere requiring continuous safety monitoring

Under these conditions, precise engineering and disciplined execution were critical to maintaining safety and schedule.

Engineering-Led Lift Planning

Prior to mobilisation, Sarens engineers developed detailed technical solutions, including drawings, lift studies, and structural calculations.

The LR 1300 crawler crane was selected as the primary lifting unit, supported by a carefully coordinated fleet that included:

• SPMTs for transport and positioning

• Terex Demag AC 220

• Grove GMK5130

• Liebherr LTM 1095

The installation sequence involved positioning the K101 unit vertically using the AC 220, followed by a 180-degree rotation executed by the LR1300 while carrying the suspended load above live refinery installations.

At certain points, crane movements were executed with as little as 10 centimetres of clearance from surrounding structures.

Temporary Infrastructure and Safety Controls

To enable the crawler crane to operate safely under load, Sarens constructed a temporary reinforced road designed to support the LR1300 during the lift.

Site preparation extended over more than one week, with safety measures including:

• Continuous gas monitoring

• Use of specialised protective equipment

• Strict compliance and permit controls

More than 20 Sarens professionals, including engineers, riggers, site supervisors, and project management personnel, were directly involved in the operation.

First Full-Scope Project in Lithuania

Artūras Dadurka, key account manager at Sarens, said the project represents a major milestone for the company in the region:

“This was our first-ever full-scope operation in Lithuania involving both a crawler crane and SPMT. The success of such a complex lift in one of the country’s most challenging industrial environments proves that we are ready for larger projects and bigger challenges.”

Supporting Refinery Modernisation

By completing the K101 installation safely and on schedule, Sarens has supported the ongoing modernisation of the Orlen Lietuva refinery, contributing to improved operational efficiency and long-term energy security for the region.

The project sets a new benchmark for engineered heavy lifting in Lithuania, demonstrating Sarens’ ability to combine global expertise with precise local execution in high-risk industrial environments.

About Sarens

Sarens is a global leader in heavy lifting, engineered transport, and project logistics, supporting complex industrial, energy, infrastructure, and petrochemical projects worldwide. Founded in 1955, the family-owned group operates one of the world’s most advanced fleets of cranes and transport systems.

Sarens is recognised for its engineering-led approach, strong safety culture, and capability to execute technically demanding operations in live and high-risk environments.

Website: https://www.sarens.com/

About Orlen Lietuva

Orlen Lietuva is Lithuania’s largest refinery and a key energy infrastructure asset in the Baltic region. The refinery plays a critical role in supplying fuel and energy products to domestic and regional markets and continues to invest in modernisation projects to enhance efficiency, safety, and environmental performance.

Frequently Asked Questions

What was installed at the Orlen Lietuva refinery?

Sarens installed the K101 deep oil refining unit, measuring approximately 40 metres in height and weighing 100 tonnes.

Why was the project considered high-risk?

The installation took place inside an operating refinery, with extremely limited clearances, live equipment nearby, and strict safety requirements.

Which cranes were used for the installation?

The primary crane was an LR1300 crawler crane, supported by SPMTs, a Terex Demag AC 220, GMK5130, and LTM 1095 cranes.

Why is this project significant for Sarens?

It represents Sarens’ first full-scope heavy lifting and transport project in Lithuania, demonstrating readiness for larger and more complex projects in the region.