News Ultra HD Time-Lapse and Video for Essar

Documenting the Regenerator Head Replacement at Essar’s Stanlow Refinery

In October 2013, we undertook a comprehensive time-lapse and video documentation project for Essar at their Stanlow Refinery. This initiative focused on the removal and replacement of a 450-tonne regenerator head, a critical component of the refinery’s residue fluidised catalytic cracking unit (RFCCU). This operation was a key element of a £23 million refurbishment project aimed at extending the unit’s operational life by an additional 25 years.

Project Overview

The RFCCU at Stanlow plays a pivotal role in the production of approximately three billion litres of petrol annually. The regenerator head, weighing 450 tonnes, is the largest of its kind in Europe and is essential for the unit’s functionality. Its replacement was necessary to ensure the continued efficiency and reliability of the refinery’s operations.

Engineering and Logistical Challenges

The replacement process involved intricate engineering and logistics. A team of highly skilled professionals was mobilised to execute the operation, utilising some of the most advanced lifting and transportation equipment available globally. This included self-propelled modular transporters (SPMTs) and a specialised skid system. Notably, components of the skid system had previously been employed in the recovery of the Russian submarine K-141 Kursk from the Barents Sea, highlighting the equipment’s capability to handle substantial loads under challenging conditions.

A significant aspect of the project was the deployment of one of the world’s largest cranes, featuring a boom extending 334 feet. This crane was essential for the precise lifting and positioning of the massive regenerator head. The coordination required for such an operation demanded meticulous planning and execution to ensure safety and accuracy.

Documentation Process

Our role was to capture the entire process through high-definition time-lapse and video footage. Technical Director Andy Piekarczyk led this effort, employing multiple cameras strategically positioned to record the operation from various angles. The documentation spanned several days, covering each phase of the project, from the initial removal of the old regenerator head to the installation of the new unit.

Given the scale and complexity of the operation, capturing clear and comprehensive footage posed several challenges. The team had to navigate restricted spaces and operate under stringent safety protocols. Weather conditions also played a role, requiring adaptable strategies to ensure consistent documentation. Despite these hurdles, the team successfully recorded high-quality footage that accurately depicted the project’s progression.

Collaboration with Essar

Throughout the project, close collaboration with Essar’s team was essential. Regular consultations allowed for a thorough understanding of the project’s schedule, specific challenges, and compliance requirements. This partnership ensured that the documentation process aligned seamlessly with the operational workflow, minimising disruptions and capturing critical moments effectively.

Final Production

The culmination of this effort was a meticulously edited video that provides a detailed account of the regenerator head replacement. The footage serves as a valuable record for Essar, offering insights into the project’s execution and serving as a reference for future operations. The video highlights the coordination, expertise, and technology involved in undertaking such a significant engineering feat.

Documenting the regenerator head replacement at Essar’s Stanlow Refinery underscored the importance of precise planning, advanced technology, and effective collaboration. The successful completion of this project not only extended the operational life of a critical refinery unit but also demonstrated the capabilities of modern engineering and project management. Our team’s dedication to capturing this process ensures that Essar has a comprehensive visual record of the operation, reflecting the meticulous efforts invested in this landmark project.