Eight coke drums replaced ahead of schedule in Canada

Eight coke drums were replaced ahead of schedule at an oil sands mining operation in Fort McMurray.

Mammoet completed a major coke drum replacement project at a Canadian oil sands facility in Fort McMurray, Alberta, delivering the work ahead of schedule and helping extend the life of the site by an estimated 30 years.

The project involved removing and installing eight coke drums, each weighing approximately 270 tonnes and standing nearly 30 meters tall, during a tightly controlled plant turnaround where every day of downtime carried significant cost implications.

Early involvement proved critical to the project’s success. Mammoet was engaged years ahead of execution to conduct feasibility studies and evaluate equipment options.

“With the importance of the project and getting everything done within a specific timeline, this turnaround was completed safely, ahead of budget and schedule,” said Kurt Reid, sales manager at Mammoet. “With the daily cost being significant, it was essential that planning happened years in advance.”

Prior to project execution, the new components were delivered to site. They were transported from their fabricator in Edmonton to Fort McMurray using prime movers on Alberta roads, and SPMTs on site.

After assessing multiple crane configurations, the team selected the PTC210DS ring crane, whose reach allowed it to be positioned away from active maintenance areas while still handling the project’s heaviest lifts, including a six-drum derrick weighing more than 1,200 tonnes.

Early preparation

Logistics planning began well before the shutdown window, with new coke drums and derrick components transported to site months in advance using prime movers and self-propelled modular transporters (SPMTs).

“Our plan was to have everything the company needed, equipment, materials and components, on site months before the shutdown so the turnaround could begin without interruption,” explained Niek de Winter, corporate account manager at Mammoet.

Dual SPMT crews operating day and night ensured a continuous workflow, while custom-fabricated rigging and a reconfigured crane setup addressed late-stage increases in component weights. The disciplined approach allowed production to continue until the day before shutdown and enabled the upgrader to return to service earlier than planned. “When you have a client planning their multi-week event down to 15-minute intervals,” Reid added, “time is of the essence.”