Project Snapshot
- Client: ABB UK Ltd
- Sector: Energy
- Location: Tilbury Green Power Plant
- Project: Offload, transport and installation of a new generator
- Duration: 4 day shifts and 2 night shifts
- Equipment Used: 35-tonne overbridge crane, specialist lifting and transport equipment
75-Tonne Generator Installation in a Live Power Plant
We were appointed by ABB UK Ltd to manage the offload, transport and installation of a new generator at Tilbury Green Power Plant. Weighing up to 75 tonnes, the generator presented a significant handling challenge, requiring specialist lifting and transport equipment to safely move it from the delivery trailer to its final position within the turbine hall.
The project was further complicated by restricted access and limited working space within the power plant. Navigating the generator through the site and into the turbine hall could not be done in a single lift as the generator exceeded the lifting capacity available inside the building.
As work was carried out within an operational power generation facility, maintaining safe access routes, segregating work areas and coordinating activities with site personnel were critical to ensure that lifting operations did not hinder ongoing operations.
Flexible Lifting Solutions for a Restricted Access Environment
To overcome the challenges posed by the generator’s size, we developed a detailed lifting and installation strategy. Following the offload, the 75-tonne generator was transferred onto skates and moved into the turbine hall using specialist transport equipment.
Compensating for the limited lifting capacity available inside the building, we then implemented a complex multi-stage lifting operation using a 450-tonne jacking system, temporary support structures and the site’s 35-tonne overhead crane. This enabled us to safely rotate, position and install the generator with the precision required for final alignment.
The project was delivered over 4 day shifts and 2 night shifts, allowing us to maximise productivity while maintaining safe access and segregation within the live facility. As a result of our team’s planning, experienced supervision and close collaboration with ABB, the generator was installed on schedule and with minimal disruption to ongoing site operations.