RTG Site Assembly R1 [PDF]

Zitiervorschau

Rubber Tyred Gantry Crane - Site Assembly Procedure

Rubber Tyred Gantry Crane Site Assembly - Man Power Description • 1.

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Structural Works Fabricators – Fabricator’s for Structural Plate Cutting and Plate Edge Weld Preparation. - Fabricator’s for General Works. Welder’s – Welder’s Pre-Qualified (6G Position) M.A.W. Welding Process – Full Penetration One (1) Side. - Welder’s for General Works. Mechanical Mechanical – Mechanic’s for Detailed Assembly, Gantry Drives, Mechanical Systems. Mechanical – Mechanic’s for Basic works including Assembly of Ladders, Access Ways, Wheel Guards,etc. Electrical Electrical – Electrician’s Pre-Qualified for Final Termination Works. Electrical – Electrician’s for Cable Tray Installation and Cable Pulling / Cable Tying. Riggers – Experienced Riggers for the Slinging & Lifting Arrangements of the Portal Structure and Assist with the installation of the balance of the modules for the RTG Crane

Cable Chain Festoon System

Head Block Assembly

Trolley & Hoist Assembly

Cabin

Spreader

Resistor Platform & Resistors

Gantry Assembly

Walkway

Bridge Girder Tie Rod Access Way Exhaust System LEG Diesel Generator E-Room Diesel Generator Sliding and Folding Access Platform Sill Beam

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Picture 1 – Lay out Bridge Girder and Leg Structures and Level – Align. A qualified Structural Surveyor with a Level Instrument and Theodolyte is required. Measure the Structures and confirm Alignments and Measure the Leg Structure to be Cut / Trimmed for the connection to the Bridge Girder. Picture 1

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Picture 2 - Cut / Trim / Edge Preparation of the Leg Structure Joint to the Bridge Girder. Note that the Weld Joint Design is Full Penetration from one (1) Side with Backing Strip. After Preparation – Tack up Structural Surveyor with a Level Instrument and Theodolyte to Confirm Alignments and Measurements. Full Penetration Weld Process Q.C. NDT – U.T. 100%

Weld Joint

Picture 2

Structure Support Stands

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After the welding process is completed, the Weld Joint and surrounding area must be Painted with the Coating Specification As per ISO 8501-1 and by mechanical power tool cleaning.

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Picture 3 – The Leg Connection to the Sill Beams must be prepared. Measurement Joint Preparation and Structural Surveyor with a Level Instrument and Theodolyte to Confirm Alignments and Measurements. Note that the Weld Joint Design is Full Penetration from one (1) Side with Backing Strip

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Picture 3

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After the Structural (Fabrication / Welding / Coating of the Welded Joints) the following items can be completed. Picture 4 (next Slide) – Cable Tray Installation Cable Installation Cable Tray Covers Installation Generator Exhaust Pipe Installation Walkway Grating Installed Crane Signs Painted (These signs are painted where the Lifting Arrangement will not damage the Signs. In these areas the signs will be completed using a Man Lift) Portal (Bridge Girder) Flood Light Installation including cabling (Photo Below) Final Paint Touch –Up where damage has occurred during installation works

Flood Light Installation

Picture 4 Walkway Gratings

Exhaust Pipe

Crane Signs Applied

Cable Trays & Cables Installed

Coating System applied after welding

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At the same time the Structural Assembly is being prepared the Lower Sill Beam and Gantry is assembled and aligned. First item of this works is to Assemble the Equalizer Beam / Wheel Fork Assembly to the Sill Beam with the Pin Connection (NCSC will Supply the Equalizer Beam / Wheel Fork Assembly ). Picture 5 (Next Slide) shows the completed assembly. Picture 5 – The following is the preparation procedure for the Sill Beam Assembly to accept the Upper Portal Assembly Connection: Install Sill Beam / Gantry Assembly to Leveled Support Stands. Again the process must be done with qualified Structural Surveyor with a Level Instrument and Theodolyte to Confirm Alignments and Measurements. The two (2) Sill Beam Assemblies (Diesel Side & E-Room Side) must be aligned centrally and together with the Four (4) corners of the Structure Leveled and Aligned The Sill Beam Assemblies and also tied with Counter Weight Blocks for Safety during the Pre-Assembly and Assembly of the Upper Portal Structure (two (2) Counterweights per side – each Counterweight 10Tons) Backing Strip installed at the Four (4) Upper Portal Connection Areas.

Picture 5 Backing Strip

Equalizer / Wheel Fork Assembly

Counter Weight Blocks

Level Support Stands

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Picture 6 (Next Slide) – The Upper Portal Assembly - weight includind Access Ways, Cable Trays and Cables = 31Ton ( 1 Bridge Girder & 2 Legs ) is lifted into position using the Following Lifting Arrangement (Note also the pre-installation of the Tie Rods) – 1 x Lifting Spreader Beam – 5T. 2 x Lifting Beams - 0.75T ea x 2 = 1.5T. 2 x Lifting Wire Rope Sling Arrangements ( Each Sling Arrangement Capacity 35T). 1 x 150 T Crawler Crane. 2 x 50T Hydraulic Mobile Crane (to Tail out the Legs during the initial Lift). After placing the Upper Structure and Sliding the Legs over the Backing Strip on the Sill Beam the Structure Alignment must be confirmed by the qualified Structural Surveyor with a Theodolyte. The Upper Portal must be re-strained by wire ropes to counterweight blocks – tensioning with Chain Blocks. Fixed Points are mounted under the Bridge Girder. The Full Penetration Weld Joint Preparation must be Q.C. Inspected and approved. After all the above has been completed the Welding Process can be completed with the N.D.T. 100% U.T. Inspection. After the welding process is completed, the Weld Joint and surrounding area must be Painted with the Coating Specification As per ISO 8501-1 and by mechanical power tool cleaning. Picture 7 (2nd Next Slide) – After the Two (2) Upper Portal Assembles are installed the Rail Distance (Shown by the Red Arrow) must be confirmed and then the Tie Rods between the two (2) Assemblies may be connected.

Picture 6 Lifting Frames Lifting – Spreader Beam

150T Crawler Crane

Tie Rods Cables From Upper Portal to Counterweight Blocks

Welding Process

Rail Distance

Picture 7

Tie Rod Connection

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Picture 8 – Generator Installation – weight 10T Generator Access Platforms Installation Sill Beam Cable Tray Installation Electrical Junction Box Installation Electrical Cable Installation and Termination

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Picture 9 – E-Room Installation – weight 8T E-Room Access Platforms Installation Sill Beam Cable Tray Installation Electrical Junction Box Installation Electrical Cable Installation and Termination.

Picture 8

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Picture 10 – Install Resistor Bank Platform and Resistors Install Access Ways and Lighting Systems

Picture 10

Picture 11 – Install Gantry Drive Assemblies (Electric or Chain Drive) Install Wheel Turning and Locking Assemblies Install Diesel Fule Tank Systems Picture 12 (next page) shows Wheel Assemblies which will be supplied by NCSC – to be installed. Picture 11

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Picture 12 - Wheel Assemblies which will be supplied by NCSC

Picture 12

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Picture 12 (a) – Install Wheel Guards and Gantry Drive Protections (noted with red arrows)

Picture 12 (a)

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Picture 13 – Cabin Assembly – Supplied by NCSC.

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Picture 14 - Cabin to Trolley Installation. The Electrical Termination Works from the Cabin to the Trolley Junction Box can be completed at the phase. The complete Trolley Assembly is the lifted onto the Crane Upper Structure and the Final Electrical / Mechanical works can be completed – weight 27T using the 150T Crawler Crane. Picture 14

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Picture 15 & 16 – Cable Track & Chain Festoon System installed and Electrical Termination works completed.

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Note – After all the Electrical Termination Works are completed a Complete Line Check to be done and the Wiring Diagram is marked up as confirmation.

Picture 15

Picture 16

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Picture 17 – Install Head Block Assembly (supplied by NCSC) and Reeve Main Hoist and Anti-Sway Rope System.

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Pictures 18 & 19 – Typical Cable Tray, Junction Box and Intercom Installation works. Picture 17

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Picture 20 – After all Structural / Mechanical / Electrical works (confirmed by Q.C.) the RTG Crane is Hand Over to the Commissioning Team.

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Picture 21 – RTG Cranes ready for Shipment and loading to Barge

Picture 21