Transport Trolleys for Nuclear Cooler

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For EPZ in Borssele, Delmeco Consulting and Engineering Agency delivered the engineering, manufacturing and on-site execution of a transport solution for the replacement of nuclear coolers at the Borssele Nuclear Power Plant.

The challenge was not only the weight of the coolers, but also the environment in which the transport had to take place. The components, each weighing approximately 12 tonnes, had to be manoeuvred through an existing installation where pipework, steel structures and other equipment left very limited space for transport operations. At the same time, the power plant remained fully operational throughout the project. As a result, there was virtually no room for improvisation during execution and every step had to be carefully engineered and prepared in advance.

Transport Trolleys

To enable the controlled movement of the nuclear coolers through the installation, Delmeco developed a set of custom transport trolleys in accordance with the European Machinery Directive.

A key design requirement was an extremely compact construction, allowing the trolleys to operate within the limited available space. Each trolley has a lifting capacity of up to 8 tonnes and incorporates lifting, driving, steering and crab steering functions. This combination of compact dimensions and high manoeuvrability enabled the coolers to be transported safely past existing installations and through narrow passages.

The transport trolleys are fully remote controlled and can be wirelessly linked together. This allows both trolleys to operate synchronously as a single transport system, ensuring the load remains under complete control throughout the entire transport operation.

Safety is further enhanced through a two-hand control principle. Each trolley is operated using its own remote control, and both operators must simultaneously authorise every movement before the system can be activated.

3D Scan

Before transport operations commenced, the existing installation was fully captured using an extensive 3D laser scan.

Based on this digital model, Delmeco engineered the complete transport route and identified all critical interfaces in advance.

By analysing the route digitally before execution, potential bottlenecks could be identified at an early stage, allowing every transport step to be carefully planned. This ensured that the complete transport sequence, including the required tooling and auxiliary equipment, was fully validated before work started on site.

Supporting Structures and Lifting Equipment

In addition to the transport trolleys, Delmeco also engineered and manufactured the required supporting steel structures and lifting equipment.

New steel support structures were manufactured in accordance with NEN-EN 1090, Execution Class 3 (EXC3). The lifting equipment was produced in compliance with NEN-EN-ISO 3834-2, ensuring that every component of the transport system met the required quality and safety standards.

Thanks to the combination of detailed engineering, purpose-built transport equipment and meticulous preparation, the nuclear coolers were safely transported within a fully operational nuclear power plant.

This project demonstrates how custom-engineered transport systems can successfully be applied to projects where the primary challenge is not only the weight of the load, but also the restricted working space and the precision required to manoeuvre heavy equipment safely.

Client

EPZ (Elektriciteits-Produktiemaatschappij Zuid-Nederland N.V.) is the operator of the Borssele Nuclear Power Plant and a producer of CO₂-free electricity. In addition to nuclear power generation, EPZ invests in renewable energy through wind and solar power and plays an important role in the Dutch energy transition.

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