Sarens Performs Precision Replacements for TCO Turnaround Project in Kazakhstan
Using extreme care, Sarens replaces reactors, column, and other elements at Tengiz facility
March 2024

The TCO plant in Tengiz, Atyrau, Kazakhstan, recently contracted Sarens to help with turnaround works at the facility. By August 2023, Sarens Kazakhstan had successfully completed all critical work for the turnaround project, including replacing a D-503.2 column, which weighed 112 tonnes, and three reactors (R-720, R-721, and R-725) weighing 56 tonnes each. Sarens also designed and supported a variety of lifting works for the project, including the installation of transformers and the replacement of hard-to-reach pipelines.

As part of ongoing operations at the site, Sarens used 18 axle-lines SPMT as well as 14 cranes, including a Liebherr LR 1600-2 (600 tonnes), Sumitomo-SCX 1500A-3 (150 tonnes), and CC2400-1 crawler crane. The Liebherr and Sumitomo cranes were mobilised from Almaty while the other oversized cargo came from Atyrau and Aktau, 427 and 700 kilometres away, respectively. They remained on-site and operational for periods ranging from 25 through 60 days, and were configured in SLDB configuration with a 72-metre main boom and 260 tonnes SL counterweight.

As part of the turnaround operation, Sarens was tasked with replacing the most critical element: the 112-tonne column D 503. The column was more than 30 years old and lacked a proper lifting lug, which made the operation a challenge for the crew. To address this, Sarens Kazakhstan and the UK-based engineering team proposed using a needle beam to lift and remove it. 

Sarens UK manufactures the needle beam specifically for this type of column, though installing it was still one of the most challenging parts of the operation. One working shift of twelve hours was needed to attach the new lifting tackles to the old column. To remove the old column and install the new one, Sarens then used a lift radius of 38 metres, completing the lifting work in less than half a day.

The team worked with extreme precision and care as they replaced the column, three reactors, and a variety of other elements. They had to manoeuvre around a narrow and congested working area that included overhead pipelines, trenches, manholes, light poles, and fire hydrants.

Finally, with the lifting work complete, Sarens project engineer Bassarov Kairat said, “Thanks to the professionalism of Sarens colleagues, all difficult tasks were completed on time and safely. This has helped earn more trust and respect from our client, TCO.”

Sarens would like to thank TCO for entrusting us with this important project, as well as the crew and colleagues who made the turnaround operation a success!