MAN Diesel PrimeServ was awarded the contract to relocate six second-hand Mirrlees engines, totalling 18MW, from an outdoor storage yard in PNG into a newly built extension to the existing stand-by power plant in Lae, PNG.

Two engineers from PrimeServ Sydney, stationed in Lae for the duration of the  project, coordinated and controlled the project. Local support played a big part in providing labour and at times special fixtures, to manoeuvre the engines and associated equipment into place.

Overcoming obstacles with practical solutions

Raising the engines onto the prime movers created a logistic problem, as suitable cranage was not available. PrimeServ overcame this by jacking the engines to a suitable height to allow the low-loader to reverse under the engines. This process was repeated in order to remove the engines from the low-loader and lower to floor level. The engines were manoeuvred into position using the converted engine-turning-gear as a chain winch.

The dismantling and movement of the engines from the previous site was carried out by others. Although every effort was made in labelling the welded sections before cutting (to enable ready identification at a later date), it soon became apparent that the labelling had suffered during the storage time. This provided an unwarranted problem, but with the aid of the original drawing, the layout of the pipe-work was accomplished, flanges welded into place and pipe-work pressure tested.

Rising to the challenge

As the contract required MAN to use as much of the existing materials, electrical cable and control equipment, control rooms and pipe-work as possible, this relocation promised to be challenging.

MAN PrimeServ successfully re-installed existing air radiators, for jacket water, lubricating oil, charge air and exhaust valve coolers, fuel oil and lubricating oil purifying systems.

In recognition of PNG Power’s unique requirements, PrimeServ was able to accomplish a rewarding outcome to both organisations.  All six engines were commissioned and tested on load and since have been operating under the control of the Lae station staff.