Vanguard delivers 360 tonne stator from Poland

The stator in transit to the Matla power station in South Africa on a 24 axle, four file, modular trailer configuration. Photo: Vanguard

Heavy transport and load installation specialist Vanguard executed a multi-modal operation to get a large and heavy load from Europe to South Africa.

The large stator, a component for electricity generation weighing 360 tonnes, had to be transported from Poland to South Africa.

The stator is the stationary part of an electric motor which transfers electrical power via a magnetic field to a rotor which can then deliver that now mechanical energy to a fan, pump, axle or similar driveline.

Size that up by some levels of magnitude to a stator used in a power station and the role is reversed in that the motor becomes a dynamo. In such applications a turbine (powered by steam, water, etc.) spins a rotor which sends charge to the stator. From there the magnetic force is harvested as electrical energy and transferred to the grid.

Over time stators in power stations can lose their generating capacity as a result of deterioration of the components and cabling. Replacing the stator can restore lost power generating capacity and extend the working life of the power station.

Unloading using the ship’s gear onto a ten axle line (6+4 line modules with power pack) SPMT to a laydown area at the Port of Richards Bay in South Africa. Photo: Vanguard

A lengthy journey

The power station in Matla, South Africa, was the recipient of the new stator. It was fitted to help regain the station’s maximum 600 MW output.

The 360 tonne component was shipped to South Africa from a specialist manufacturer in Wroclaw, Poland, by Vanguard which managed every leg of the move.

In a multi-modal operation, the move started with rail transport from the production facility in Wroclaw to the Port of Gdansk. This part of the journey required the use a schnabel (beak) wagon at each end of the component to ensure its safe delivery.

From there the stator was transferred to a temporary handling area before being loaded onto the shipping vessel. That ship went on to arrive in the Port of Richards Bay in South Africa where, due to a port embargo, Vanguard was required to discharge the stator at the company’s laydown area.

Vanguard offloaded the stator using its Cometto MSPE self propelled modular transporter (SPMT) in a 10 axle, four-file configuration, moving it to a laydown area. From there it was transported about 700 km to the Matla Power Station using a 24 axle, four file trailer configuration.

Dangerous roads

Steep hills were among the biggest challenges on the lengthy trip from Poland to South Africa. Photo: Vanguard

The road transport phase presented significant challenges, including travel through KwaZulu-Natal, a region of South Africa sometimes referred to as “the valley of 1,000 hills.” Its steep terrain had some demanding ascents which required careful planning, particularly due to the four truck tractors at both the front and rear of the load.

The three-week journey was further complicated by poor road conditions and even some of the most severe storms seen in the region over that year.

Manoeuvred into its final position using a six-axle, four-file SPMT combination, the stator was then lifted and installed using Vanguard’s 800 tonne hydraulic gantry system. The need for precise placement called for considerable engineering expertise.

“Vanguard’s successful delivery of the stator further reinforces our position as a trusted partner in the power generation sector and a leader in delivering large scale, technically demanding logistics projects across global markets,” said Laura Hodgkinson, Vanguard director.

She continued, “This project demonstrates Vanguard’s ability to deliver complete project solutions, from project cargo, international transport and port operations to overland transportation and final installation. By managing every stage of the process, Vanguard ensured efficiency, reliability and the highest standards of execution for complex heavy lift projects.”

On arrival at the power station Vanguard used an 800 tonne hydraulic telescopic gantry lifting system with two pairs of legs and two header beams. Photo: Vanguard