Worldwide heavy transportation and lifting

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Challenge acceptedALE’s 10,000t record-breaker

Worldwide heavy transportation and lifting

Summer 2019 | www.ale-heavylift.com

COMPANY NEWS

NEW RENEWABLES COLLABORATION INCREASES PORT SERVICES

EQUIPMENT NEWS

MEGA JACK 300 FLEET GROWS

PROJECT FOCUS

17,000T JACK-UP IN MEXICO

PEOPLE

LIFTING THE LOAD ON… LAURA DAVIES, PROJECT MANAGER

CASE STUDIES

INCLUDING KAZAKHSTAN’S LONGEST-EVER TRANSPORTATION

SECTOR FOCUS

RENEWABLES – WIND

SK10,000

Stronger has a new nameALE has announced its latest record-breaking innovation – the huge SK10,000 craneWith an exceptional lifting capacity of 10,000t, the SK10,000 takes the mantle of the world’s largest land-based crane from the AL.SK350. It will enable new levels of project efficiencies in schedule certainty, reduced risk, increased safety and cost reduction for our clients.

Demand for the lifting of larger and heavier modules for FPSO and FLNG construction is growing as clients recognise the benefits this construction methodology can bring, and our own AL.SK350 has performed world record module lifts in the range of 3,000t. The SK10,000 will allow modules to be installed directly onto ships’ hulls, far in advance of what has been conceivable to date in terms of both lift weights and impact on project efficiency.

Crucially, the SK10,000 utilises the same design as the AL.SK190 and AL.SK350, which have opened new possibilities in FPSO construction and have been proven successful across the globe in many major projects. The new crane has been developed to deliver unparalleled lifting capacity with a similar footprint and ground bearing pressure to the AL.SK350, as well as a number of other key advantages:

• Huge outreach with jib of up to 200m (655ft).

• Low ground bearing pressure.

• Winch hoisting system – with various hook blocks to maximise lift capacity and hoisting speed.

• Small plot area. Central ballast design eliminates the need to install a full ring or crane track unless it is required for the project, reducing occupancy of the lifting area by up to 45%. This is ideal for busy shipyards or restricted access oil refineries and petrochemical plants.

• Single hoist point means modules can be lifted, rotated and positioned simultaneously.

• Reduced on-site disruption. Its large lifting radius allows the crane to be fully rigged and operated off-plot, with fewer lifting positions and less ground preparation. Foundation work can continue while critical pieces are installed, minimising disruption, reducing schedule and lowering cost.

• Simplified logistics and assembly. Containerised design and fast assembly minimise mobilisation and assembly time. ALE’s specialists can assemble the crane in a matter of weeks using standard plant and a crawler crane.

Ronald Hoefmans, ALE’s Group Technical Director, commented: “ALE is widely recognised as the leader of innovation in our industry and continues to develop ground-breaking solutions. With our innovations in lifting super-heavy modules for projects such as FPSO and FLNG construction, ALE offers important advantages in terms of managing safety and minimising project schedule and costs.

“We not only solve our clients’ existing challenges, but also look to the future in enabling our clients to achieve industry firsts that later become the industry standard. These are benefits that our existing AL.SK190 and AL.SK350 cranes are already delivering, and the introduction of the SK10,000 takes this to a whole new level.

“This means that individual lifts of up to 10,000t are now possible, allowing clients to build larger modules more efficiently in fabrication yards and access a highly mobile and flexible solution to lift them.”

Watch the SK10,000 here...

WELCOME... To the July issue of the ALE newsletter, with the latest news about the world of ALE

It’s a huge privilege for me to be able to write the foreword to our latest newsletter. Being part of a business that continues to innovate and define our industry is a real personal pleasure.

The last time I wrote the foreword to this newsletter, the oil and gas world was moving into a downturn, which has since proven to be prolonged and

deep, but we are starting to see the return of capital investment and growth in the sector. During this period, we have diversified and invested: in being the first major company in our industry to achieve ISO45001 accreditation; in specialist offshore companies; by increasing our wind activities significantly; through expansion in the USA and by innovating more in our specialist equipment.

We’ve developed a whole series of Mega Jack equipment that is spread around our business and allows our clients to install their equipment more efficiently and safely. We’ve pioneered the use of tower cranes for installing onshore wind turbines more efficiently

and with less down time. We’ve also built and deployed our second world-leading AL.SK350 5,000t crane. At the Offshore Technology Conference in Houston in May, we launched what is by a huge margin the world’s largest onshore crane, the SK10,000. We’re looking forward to securing our first project for the crane, when no doubt it will be lifting some of the world’s largest modules. We’ll be the first to tell you when it does!

None of this is possible without the foresight, dedication and commitment of our staff. Whether on site, in the yard, regularly traveling or office-based, our people listen to and fulfil customers’ needs like no one else. Working together, we deliver real benefits above and beyond our competitors to set new industry standards.

And so for our clients reading this, wherever you are based, please be assured that ALE is striving to make your world Smarter, Safer, Stronger.

Michael Birch Global Sales Director

AL.SK190 – 4,300t

AL.SK350 – 5,000t

SK10,000 – 10,000t

Lifting capacity:

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ALE’s heavy lifting capabilities recognised in space satellite transportationALE has received an award for their role in the delivery of an Argentine satellite, SAOCOM 1A, for CONAE to be launched in a Space-X rocket.

Recognised for their participation and commitment, ALE drew on their multi-service capabilities and undertook considerable co-ordination with third parties during the project. ALE’s long-standing heavy lifting experience enabled them to work with stringent risk management and quality control requirements throughout.

“We are delighted to receive such great feedback from the client and have our team’s dedicated professionalism formally recognised, having strived to satisfy them by delivering a complex, successful operation to schedule,” commented Pablo Artusi, ALE’s Sales Manager.

“We are hugely proud of ALE’s work as the main contractor on this project, and to have contributed to this great milestone in Argentina’s space programme development.”

ALE transported the satellite, weighing 12t, from its fabrication yard to Bariloche airport using a convoy of over 12 vehicles. ALE then lifted the satellite and it was loaded into an Antonov plane, ready to be launched at Vandenberg air field. Once this stage was completed, ALE went on to perform the transportation of ancillary equipment within the USA and the maritime transportation of remaining components back to Chile and overland to Argentina.

ALE crowned as ‘Excellent Employer’ in National Transport Awards

A recent pilot programme in ALE’s Breda branch for sustainable employability has enabled them to achieve the ‘Excellent Employer’ award from the Sectorinstituut Transport en Logistiek (STL), the national institute in the Netherlands that encourages sustainable employability in the transport and logistics sector.

ALE received the exemplary accreditation due to the enormous uptake they have achieved with the new programme within the company. The human resources programme, which started in September 2018, is focused on supporting people to stay in work and develop with the company. This involves managers undertaking a professional coaching course online to get the best out of their employees and encourage conversations with their teams about their future careers. In addition, employees have access to different wellbeing courses to optimise their lifestyle.

“It is the first time the STL have run such awards, so it is an honour to be the first company to be awarded,” explained Christine Kwantes, who manages Human Resources in ALE’s Breda branch.

“Our people are at the heart of the business. Since we started our pilot programme, we have noticed a 90% uptake within just two months. This is fantastic and demonstrates the importance we place on developing our people and expertise for the long-term growth of the company.”

Bespoke jacking system delivered for nuclear decommissioning ALE has delivered a unique jacking system for the removal of a reactor core on a nuclear decommissioning project in the UK. The company used its in-house steel fabrication capability to tailor-make the steel structure for the jacking system based on its Mega Jack 800 technology.

The project started in 2017 when ALE was tasked with designing, manufacturing, testing, installing and operating the core jacking system for the removal phase of an out-of-service nuclear reactor in the UK.

Because there was no commercial off-the-shelf system fit for purpose, ALE took its Mega Jack 800 jacking system and tailored it to meet the needs of the project. The team created an extended feed-in system for the lifting cassettes, a unique turntable to sit underneath the reactor, an interface system, a recovery frame, a containment tray, gutter tray and effluent management system.

“Our Mega Jack 800 typically consists of four 800t-capacity towers that are made up of layered cassettes that are fed-in while the load is raised using hydraulic pressure,” explained Sandy White, Regional Engineering Manager at ALE.

“The space restrictions on the project site meant we could only use one tower. The jacking system also had to be built with a recovery frame to ensure there was a redundant fail-safe in place. As a result, we’ve designed the jack with a skidding system that can be moved into position underneath the reactor to safely lift the reactor by 8m from its enclosure to be dismantled.”

“The construction of the customised elements of the project was made possible using our own fabrication facilities at our Hixon branch in Staffordshire, UK,” continued White. “The facility excels in using a variety of the latest steel fabrication techniques to ensure we can deliver a customised solution for every customer need, no matter how demanding.”

ALE’s fabrication capability is accredited to CE standards, including the higher Execution Class 3 level under BS EN1090, a European standard that regulates the fabrication and assembly of steel and aluminium structures. The project has been executed in several stages and is expected to be completed in the second half of 2019.

ALE’s agreement with Port of Dundee and OM Heavy Lift increases port services for renewables sectorALE has expanded its heavy lifting services by establishing an agreement with the Port of Dundee and OM Heavy Lift to provide the full service of port operations.

ALE signed the agreement with OM Heavy Lift, a subsidiary of OilMac who recently bought ALE’s Gottwald MK1500 crane, and the Port of Dundee.

Greater renewables heavy lifting scopeALE will be working alongside OM Heavy Lift, with the use of their heavy crane, and the port, who currently work with offshore wind and decommissioning clients in the North Sea, to provide a more complete heavy lifting and port handling scope of work to the renewables market.

With many years of experience, the three companies are ideally suited to combine their assets and provide the storage as well as port handling of offshore modules.

Increased services for offshore and decom“We are pleased to be working together to optimise our services to the ever-evolving renewables sector,” explained Chris Taylor, Commercial Director for ALE. “The Port of Dundee is becoming an increasingly big player in the offshore markets and, by promoting our services together, we can really optimise these opportunities and provide a fully integrated service to our clients.”

Alex Fyfe, Managing Director at OM Heavy Lift, said, “We’re anticipating our heavy crane capability to be a significant attraction for offshore wind developments. The Gottwald MK1500 is a vital asset for future offshore wind and decommissioning projects in Dundee and will propel our business in the medium term, and beyond.”

David Webster, Port Manager at the Port of Dundee, said, “A permanent crane removes mobilisation charges, which is important in a competitive market.”

“We place significant emphasis upon the decommissioning and renewables construction capabilities at the Port of Dundee, and it becomes ever more attractive in this field as OM Heavy Lift’s Gottwald MK1500 and Olympus cranes mitigate those cranage costs.”

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Company News

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Specialist cranes aid schedule and costs on major south-eastern Australia wind project

Three new cranes aimed to reduce costs and footprint have arrived into south-eastern Australia in preparation for a major wind project.

The cranes, including an AC700 all-terrain crane, a LTM1750 all-terrain crane and two LG1750 mobile cranes are specialised for the wind handling activities.

These mobile cranes are ideally suited for this project as they can travel on roads less than 6m wide, reducing their environmental footprint and saving unnecessary time and costs on civil upgrades.

ALE has been contracted to install 60 wind turbine generators at the Lal Lal project site. Starting in November 2018, ALE has used its expertise in wind services and heavy lifting for the installation of the first two wind turbines.

Conbit enhances offshore lifting capabilities with new knuckle boom craneALE’s Conbit operation has enhanced its rental crane fleet by investing in a new knuckle boom crane that is ideal for specialist offshore lifting.

Versatile offshore craneThe CK050F temporary offshore lifting crane is a telescopic knuckle boom, which is designed for offshore lifting and is ATEX certified for offshore applications.

The crane allows operation of multiple functions simultaneously (slewing, luffing, lifting) and has a continuously variable speed control, from zero to maximum speed. It is extremely versatile as it has the capacity to lift up to 9.7t on platforms or at harbours, or up to 5t for wave heights up to 2.5m.

Compact and easy handlingWith its small footprint, it is hugely beneficial for deck crane replacements, maintenance, wireline services and installation operations on offshore facilities where there is often limited space and no regular cranes available.

The crane can be easily deployed anywhere in the world as it can be disassembled into small components and containerised for easy handling.

“By introducing this unique crane into our fleet, we can really strengthen our offshore lifting capabilities and offer a crane that is ideally suited to many different applications. It is lightweight and versatile, making it hugely beneficial when there is restricted site space and limited lifting resources,” explained Bram van Oirschot, Tender Manager for Conbit.

ALE-developed technology eases transition piece handlingALE is optimising offshore wind project costs by designing a unique new modular transport frame specialised in carrying transition pieces (TPs) within marshalling ports.

Alternative port transportation

Designed in-house by their award-winning R&D team in Breda, the Netherlands, the new Transition Piece Carrier has been developed as a more cost-effective alternative for transporting the TPs rather than using cranes to handle them.

Overall project efficiency is delivered as the system can move within limited spaces, which optimises storage, can operate

at higher wind speeds and is not limited to the TPs’ diameters or weights. As additional steel frames are not required, it enables the TPs to be simply positioned onto the current concrete blocks – which are readily available and are a more cost-effective storage option.

Safer transport for larger TPsFurthermore, as the TPs are increasingly growing in size and weight, the carrier is ideal because it can transport TPs weighing in excess of 600t and is flexible enough to transport TPs with different base designs.

It also provides a safer transport solution as it eliminates the need to work at height.

“Offshore renewables is a huge growth market for us and we wanted to ensure we had the optimal solution for port handling operations for our clients,” explained Technical Sales Manager Tomas Villarino.

“This is a highly beneficial solution that aids project efficiency and cost reduction, with optimised working conditions that will be compatible with the ever-changing design of TPs to future-proof our offering in the sector.”

The launch of the system coincided with the release of ALE’s new brochure.

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Equipment News

ALE expands Mega Jack 300 fleet and capabilities in EuropeALE has expanded its Mega Jack 300 fleet, the next-generation jacking solution, throughout Europe for upcoming civils projects.

Innovative jacking systemLaunched in 2018, the latest jacking innovation is a compact and versatile system that enables site optimisation and project efficiency. The Mega Jack 300 offers a superior solution to traditional climbing jacks in a wide variety of applications.

ALE will be delivering a multi-point system to its UK branch, bringing the total amount of towers in the Group’s global fleet to more than 20.

A compact lifting solutionThe system was designed in-house by ALE’s R&D department for a cost-effective solution to jack-up heavy modules on sites where space is restricted or congested in short periods of time. The system has already demonstrated its time efficiency, increased stability and compactness while jacking-up hundreds of pipe rack modules over 7m high in Kuwait. 16 towers were operating together to deliver safe and quick operations. (See more on page 8.)

“We are delighted to have this innovative system operating in the UK. We have secured several civils projects where this system is ideally suited; it will demonstrate the system’s strength and capabilities to optimise project schedules,” explained Russ Jones, Director – UK.

A number of bridge projects are lined up to benefit from the new system across the UK in 2019.

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PROJECT NEWS

OVER 180 FAST JACK-UPS BOOST REFINERY CONSTRUCTIONin Kuwait

SECTOR: OIL, GAS & PETROCHEMICAL

KEY BENEFITS: QUICK OPERATIONS » INCREASED STABILITY » LIMITED SITE SPACE

PROJECT:The Mega Jack 300’s versatility and efficiency has been demonstrated as it jacked-up, transported and installed a series of modules over 7m high in Kuwait.

New record for KuwaitThe pipe rack modules included the longest and highest of their type that has ever been jacked-up, transported, and installed in Kuwait. With their considerably high centres of gravity, ensuring stability was essential. By utilising the Mega Jack 300’s unique balance and low starting height to pick up loads directly from SPMTs, ALE was able to perform the jack-up of such tall and heavy modules securely.

In one case, a module was first jacked-up 7.2m in just two hours and then transported on widening trailers 2.7km to its installation location. Despite limited clearance between the packing system and the Mega Jack 300, the accuracy of the control systems and the experience of ALE’s operators ensured it was safely managed.

Expert engineering designAs the work at site was progressing, ALE needed to ensure a more efficient hydraulic group configuration that was wider in order to navigate the tight corners and maintain a higher trimming value. ALE’s engineers opted for 76 axle lines of SPMT in a 4 file 38 configuration. Once in position, the module was lowered into position using the stroke of the SPMT.

“We are delighted to be providing the full onshore heavylifting solution for one of the largest refineries in the Middle East,” explained Sarkis Juvelekian, Senior Project Manager.

“Our engineering team have overcome many of the challenges, such as limited clearances, with the ability to jack-up high while maintaining stability; all in a safe and efficient manner. Our performance not only illustrates the Mega Jack 300’s ability to handle these modules in the most suitable way, but also the expertise of the team involved.”

Versatile jacking abilitiesAs the modules are so different in their make-up, this jacking system provided the flexibility, compactness, lift capacity and speed required.

This system is the latest addition to ALE’s Innovation Series and the third in our jacking range, supplementing the Mega Jack and Mega Jack 800 systems. It has 300t capacity per tower and is much lighter and more compact than the previous models.

ALE’s latest jacking innovation is vital to the successful completion of Package 2 and 3 of the KIPIC Al Zour Refinery Project, which involves the jack-up, transportation, and installation of 188 pipe rack modules varying in size, weight and foundation heights.

Watch the project here…

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PROJECT NEWS

ALE PERFORMS 13,000T JACK-UP AND LOAD-OUT to upscale Mexican yard

SECTOR: OFFSHORE

KEY BENEFITS: INNOVATION » REDUCED COSTS » REDUCED RISK

PROJECT:ALE delivered an integrated solution to help complete a phase of a major offshore project in Mexico – the largest in terms of size.

The global heavylifting contractors were tasked to perform the weighing, jacking and load-out of the jacket and the platform.

The first stage of the three-phase project involved the 14m-high jack-up of the topside, weighing over 13,000t, using ALE’s innovative Mega Jack system. As the Mega Jack has its own starter beams, and has quicker assembly and jacking speeds, it is much more efficient than other systems on the market.

Expertise of specialist offshore teamFor the load-out of the topside, ALE – Offshore Services was the specialist team who designed and supplied the rapid ballasting system – with a system capacity of 16,000 Cu.M/Hr – as well as the associated ballast pipework, specifically for this operation.

With a combined weight of almost 17,000t, the topside was pulled a total distance of 196.63m using strand jacks and kicker jacks to complete the load-out onto the client’s barge in a timely manner.

Health, safety and the environment (HSE) was a paramount consideration throughout and underpinned the entire project. ALE ensured all operations were supervised centrally in real-time to ensure operational flow.

“This is a fantastic achievement for all of the ALE teams involved. Throughout this project, we have established a strong on-site partnership to meet our client’s technical and operational needs,” explained Simon Armstrong, Project Manager for ALE – Offshore Services.

“By finding a solution that could integrate our systems easily with the client’s needs, we delivered an effective methodology, and the proven upscaling of the yard makes it a more attractive site for future operations.”

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PROJECT NEWS

ALE performs first 5,000t load application test operation in London city centreALE has used its in-house expertise to design, supply, install and perform a bespoke on-site load application – the first load test of its kind in Europe – when conducting the progressive loading of a test pile in central London, UK. At 5,121t, it was also the highest load test on a pile within Europe.

ALE’s testing equipment enabled the ground model to be confirmed on site for the future main build structure of the new 21 Moorfields building, a mixed retail and office redevelopment. The client supplied the load schedule of the 16-storey building’s test pile up to a maximum load of 50MN (circa 5,000t).

Bespoke load test solutionSpecialist weighing equipment needed to be positioned prior to the commencement of test truss assembly. The pile test loading and unloading cycle fluctuated in load up to a maximum of 52.2MN in line with the engineer’s requirements. The test then took place over a three-day period, running 24 hours a day.

“Our unique method allowed for a very progressive and accurate load application with real-time monitoring,” explained Project Engineer Pete Cox.

Time-saving methodology“Using this method meant our client had the insight that our solution was able to distribute the load across a varying number of reactive piles during the load application sequences. Not only does the client now have the confidence that this monitoring and control solution can be implemented for their load schedule for the pile test criteria, but there is the potential to apply this high load test time-saving methodology on other sites.”

The load test operation was completed in September 2018. ALE is currently preparing for the additional scope for the 21 Moorfields project, which involves the removal of a construction plant with specially-designed high-level grillage.

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PROJECT NEWS

ALE completes combined 6,614t lift with world’s largest capacity craneALE has lifted over 7,000 US tons using the world’s largest capacity land-based crane for an oil and gas project in Texas, USA.

The significant 354,000t/m load moment and long outreach of the AL.SK350 enabled the global heavylifting specialists to lift the living quarter module – the third of three modules – on top of the offshore topside. The final module, weighing 2,234t (2,462 US tons), was lifted on 2nd March 2019.

Time-saving single lift locationThe three modules, weighing a combined total up to 6,614t (7,290 US tons with block and tackle included), were lifted using ALE’s unique AL.SK350 crane for the project in Ingleside. As the crane can lift from one position, this is the ideal solution for working in the congested site and significant time is saved by not needing to relocate the crane for every lift, as would have been the case with other ring cranes.

The AL.SK350 has been rigged with a 124m (406ft) main boom, and 49m (160ft) ballast radius, along with a heavy winch system and 4,000t (4,409 US tons) ballast.

The third lift, involving the living quarter module, took place in March and weighed a combined total of 2,234t (2,462 US tons with block and tackle included). For this, the installation outreach was 42.8m.

Experience and unique abilities“As we come to the end of the first phase, we are proud of the professionalism shown throughout. Our experienced crew, working alongside our crane with such unique abilities, has enabled us to achieve these heavy lifts in a challenging site environment. By using the latest technologies, we could carry out the lifts safely and on schedule while minimising disruption to the rest of the busy site,” explained Ronnie Adams – Senior Project Manager.

In order to avoid delays to the overall offshore topside projects, these lifts acted as a trial to ensure the modules fit and the topside is pre-commissioned, ready for when it is installed using a new heavylift vessel off the coast of Israel.

PROJECT NEWS

OFFSHORE EXPERTISE ENABLES DOUBLE JACKET LOAD-OUT in India

SECTOR: OFFSHORE

KEY BENEFITS: EXPERIENCED TEAM » LONG-STANDING RECORD OF SIMILAR WORK » CLOSE WORKING RELATIONSHIPS

PROJECT: The expertise in strand jack pulling load-outs of ALE – Offshore Services’ team was vital to ensuring the successful and safe load-out of two 4,000t jackets in Chennai, India.

The team had developed a close working relationship with the client and, combined with the successful track record from previous operations meant the client had the upmost confidence in ALE’s abilities.

ALE provided all the necessary preparations, including the ballasting and mooring calculations.

Each jacket was loaded-out within one month of each other and was loaded-out with the strand jack pulling technique in conjunction with the ALE load-out ballasting plan. ALE’s versatile mooring and winching equipment was deployed during the load-out operations too.

“Moving loads like this is second nature to us, but our client needed the reassurance that it could be achieved safely with the necessary timescales to industry safety and quality standards. By working closely and remaining open, recognising each other’s strengths and demonstrating our portfolio of similar operations, the client had confidence in our abilities. In fact, we were praised for our preparation, control, as well as our professionalism and calmness shown throughout,” explained Dan Kempin, Business Development Manager for ALE – Offshore Services.

The jackets form part of the Bassein Development 3 Well Platform and Pipeline Project, the development of three oil and gas fields, in India.

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PROJECT NEWS

OFFSHORE EXPERTISE KEY TO DOUBLE TOPSIDE TRANSVERSELOAD-OUTin Oman

SECTOR: OFFSHORE

KEY BENEFITS: TRANSVERSE LOAD-OUT TRACK RECORD » IN-HOUSE NAVAL EXPERTISE » MANAGEMENT AND CO-ORDINATION OF SIMULTANEOUS OPERATIONS

PROJECT: ALE’s experience in combining multiple load-out scopes, including strand jack pulling, barge ballasting and mooring, was instrumental to ensuring the safe and successful load-out of two 7,000t topsides in Sohar, Oman.

The project’s greatest challenge was that both load-outs needed to be completed transversally and this required the topsides to be transported across the width of the barge. ALE would also need to consider the critical effect of the tidal variations on the manoeuvre. Compared to a longitudinal load-out, ALE would be working with a much finer margin of error to maintain the barge’s stability for a safe operation.

ALE utilised the engineering expertise of an in-house naval architect to develop a pattern for the manoeuvres that would ensure the most effective operation. Combined with close co-operation and communication between other contractors, ALE was able to co-ordinate the ballasting with the strand jack pulling speed. Taking the rise and fall of the tidal levels into account, ALE was able to keep the barge stable and level with the quay throughout the transversal manoeuvres and load-out.

Matt Hodgson, Engineering Manager for ALE – Offshore Services, commented, “Transverse load-outs demand the best in offshore expertise to deliver efficient operations with the highest safety standards. The narrow window for the righting moment meant we had to anticipate the next ballasting phase whilst simultaneously considering the strand jack pulling speed. This process was the fulcrum of the operation and we were able to draw on our experience from previous transverse load-outs, ensuring ALE could provide a safe, stable and efficient operation.”

Both topsides will form part of the expansion of the Hasbah gas field, which is part of the Wasit Gas Program in the Arabian Gulf.

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PROJECT NEWS

ALE completes innovative and cost-effective marine scope on world’s biggest offshore wind farm projectALE has used their offshore engineering expertise to complete their full scope of work on one of the biggest offshore wind farms in the world, Ørsted’s Hornsea Project One.

Specialist offshore collaborationAs well as deploying new and innovative equipment for the first time, ALE has been able to utilise the experience of their Conbit operation for the project’s structural engineering to provide a cost-efficient and safer solution for the project.

ALE was contracted by GeoSea to provide the specialist offshore engineering alongside the marine transportation, sea-fastening, load-out and ballasting of over 100 transition pieces (TPs) in the UK.

ALE’s scope on the project began with the load-out of the TPs, each weighing 337t and measuring 25m high, from the fabrication yard onto the barge. Conbit provided the engineering for cost-effective storage and SPMT stability during the ALE transport operations at the yard. For the structural engineering, the Conbit team performed the structural integrity and sea-fastening calculations of the grillages on the barge deck of the SARAH S barge. Once on the barge, the TPs were transported on the River Tees to the discharge berth.

HSQE

Debut of SARAH S bargeThe project was the inaugural job for ALE’s innovative SARAH S barge. It is 3m narrower than most North Sea barges, making it ideal for this project, as the barge could fit between the quayside and the offshore installation vessel, and also fell in line with the vessel’s crane radius limits for transferring the TPs from the barge to the installation vessel.

“We are delighted to have successfully completed our scope for Ørsted’s Hornsea Project One. This has been a long-term project and ALE provided the full, specialist marine scope of work for these operations, which, combined with the strength of the ALE - Conbit collaboration, has demonstrated the breadth of ALE’s expertise,” commented Steve Small, Commercial Manager – Marine.

The project concluded in February 2019 when ALE completed the final discharge of the 106th TP onto the installation vessel.

ALE’s commitment to safety innovation is recognised by new ISO 45001 accreditationALE’s position at the forefront of safety best practice in the heavylifting industry has been recognised with the achievement of a new global HSQE accreditation, ISO 45001:2018.

The certificate recognises companies that demonstrate a clear commitment to health and safety management accountability across all levels of management. It highlights businesses that have developed proactive health and safety practices for continual improvement, balancing risks and opportunities, while also maintaining employee engagement and commitment.

The new high-level occupational health and safety management framework is internationally recognised, aligning it with other global standards, such as ISO 9001 and ISO 14001, which ALE is already certified in.

Gary Hewitt, Group HSQE Manager, commented, “Safety is the core of ALE’s operational activities and ISO 45001 provides a robust framework in which to measure the effectiveness of those operations. Achieving this certification is a demonstration of the proactive risk management and prevention measures in place that mitigate any potential threats to employee health, safety and wellbeing.

“We are proud that ALE is ISO 45001 certified as this identifies the best practice present throughout all levels of the organisation, showing ALE to be at the vanguard of safety management in the heavylifting industry.”

Operational standards and safety rewarded by FPSO client in SingaporeALE’s operational expertise and focus on safety has been recognised with the ‘Best Safe Supervisor Award’ granted by the client on a recent FPSO project in Singapore.

The operational team of six were praised by the client: “Your willingness to step up and go beyond your responsibilities is highly commendable. Thank you for your continual dedication to safety.”

ALE was tasked with transporting, lifting and installing eight modules, weighing up to 1,820t, onto an FPSO for the Liza Destiny FPSO project. Once complete, the FPSO will be located 190km offshore in the Liza Field and is expected to produce up to 120,000 barrels of oil per day.

“It was the first time we had worked with this particular client and they had the confidence in our abilities from our proven track record in the region,” explained Roberto Radicella, General Manager for ALE’s Malaysia branch.

“The client has recognised our professionalism and skill. We have a huge focus on in-house training and ensuring our operators have internationally-consistent standards of regular training, as well as a proactive focus on safety excellence, so we can deliver the highest level of quality on site. The fact that we only required six operators to undertake this project, less than half the crew other companies have previously deployed, is a good indicator of the expertise and capability we have within the team.”

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Q: When did you join ALE?

A: I joined ALE in June 2013 for an industrial placement year as part of my university degree. I was inspired by the opportunities that were available within the business and the projects we were working on. It was a fantastic experience, so I was excited to return to ALE in September 2015 after I had graduated.

I have spent the last few years in various ALE branches, including Australia, the UK and Thailand, working on a range of projects across different sectors. This has been a great opportunity to develop my engineering, management and operational skill set.

Most recently, I made the decision to move into a site-based project role to develop my experience on large scale projects. I moved to Thailand and began working on Wind Energy Holding’s Thepharak wind farm project. This finished in early January 2019, so I am now

back in Australia, based on site near Melbourne in a similar, site-based wind farm role.

Q: Describe your role and what it involves?

A: I am currently Project Manager on the Lal Lal wind farm project in Australia. Most of my time is spent planning and scheduling works to optimise the crane movements, managing the budget and supporting the site team wherever required. There is a great team on the wind farm, and within the whole group that provides all the mechanisms for the project to be a success.

Q: What is a typical day like?

A: My standard day involves a pre-start with the full team at 6:30am, co-ordination with our subcontractors, providing engineering support, and keeping the client updated by reporting our daily progress at the end of each day. My biggest focus at the moment is analysing the processes and resources on site to make the crane relocations as time and cost-effective as possible.

Q: What changes have you seen since you’ve been in the role?

A: Having worked in different areas of the business, I’ve been able to see changes across the whole company. I have definitely noticed an increased focus on developing individuals within the business,

which I think is great. My proudest moment recently was being asked to take on a Project Manager role and it’s been possible due to that support.

Q: What would people never guess you do in your role?

A: People are surprised when I describe my job in general. The construction industry is still male-dominated, especially on site, which could seem challenging to an outsider. However, throughout ALE there is a culture to succeed together. Working on site is one of the most enjoyable parts of my job and there are opportunities to learn from a diverse range of people.

Q: What is the most important thing you have learned so far?

A: The importance of planning and engineering the smartest way to complete a project to optimise the project resources available. The work on a wind farm is very fast-paced so decisions have to be calculated and made at the right time.

Q: What do you enjoy most about working for ALE?

A: The opportunities available to work in different locations, with skilled people, and the exposure to such a large variety of projects.

Q: Advice for someone just starting with ALE?

A: Aim high and make the most of every opportunity.

LIFTING THE LOAD ON… LAURA DAVIES, PROJECT MANAGER

ALE shares heavylifting expertise at crane industry seminarALE presented its heavylifting expertise as part of an industry seminar on cranes in Essen, Germany.

Marcel Bruijs, Sales Manager, was sharing ALE’s experience from the demolition of an overhead crane in Gent, Belgium. ALE was able to remove the crane, weighing 864t, in just 10 days using the innovative Mega Jack system, which offered a narrower solution than other alternatives and enabled the client to continue working around the Mega Jack.

The seminar on ‘Conversion, repair and modernisation of cranes and hoists’ aimed to provide those in the crane industry with practical advice on the application of current regulations and safety standards. A second similar event will be held at the House of Technology in Essen, Germany, from 18th-19th November 2019.

Watch the project here...

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ALE engineer inspires next generation of women in STEMALE was represented at an Inspirational Women in STEM event, celebrating women’s involvement in science, technology, engineering, and mathematics (STEM), in Birmingham, UK.

Inspirational womenDaisy Partlow, Project Engineer at ALE, was looking to inspire future talented engineers by speaking about some of the women who inspired her to pursue a career in STEM, which led to her working as an engineer on major heavylifting projects at ALE.

“It’s a fantastic honour to be asked to increase the profile of women in STEM and encourage others based on my own experiences. A large part of my university life was based around working with the STEM community to celebrate the success of people in those fields and I wanted to continue that,” said Daisy.

“Having previously been involved with a variety of initiatives, since I’ve been working as an engineer with ALE I have been even more passionate about inspiring young people to pursue a career in STEM subjects. Engineering expertise is at the centre of what we do and my career in STEM has already given me such a variety of interesting experiences. It’s important to share this and inspire the next generation of women in STEM.”

Growing engagement in STEMThe Inspirational Women in STEM event featured women from a variety of sectors with the aim that by speaking about those who have inspired them, they will in turn inspire other women to pursue a career in STEM. The evening was part of STEM Social, a series of quarterly networking events that seek to increase engagement among the STEM community.

Following this, Daisy attended a ‘Forge Your Future’ day at a local secondary school. The event brought together alumni and young professionals, aiming to help challenge teenage girls’ perceptions of science and engineering and provide a better understanding of the opportunities and experiences that STEM career paths can offer.

Innovative heavylifting experience shared with future civil engineersALE has shared their extensive experience of civil engineering projects during a special lecture to future civil engineers at the National College for High Speed Rail in Birmingham, UK.

Javier Martinez Gutierrez, Executive Director, was invited to give a master class on ‘Smart and Innovative Heavylifting Constructability Solutions for the Civil Engineering Market’. Speaking to students of the college, Javier shared new construction methodologies for bridges and other large structures, providing examples of the variety of ALE projects that have been carried out for the rail industry in numerous countries.

Variety of career options“Civil engineering opens a diverse range of careers for young people. ALE is always seeking innovative solutions to the challenges of this constantly-evolving sector, where clients are often looking for a swift solution that minimises disruption. We hope to see exciting new ideas coming from the engineers of the future, so it’s an honour to be asked to share the expertise ALE has developed so far and hopefully the college’s students have found it inspirational,” commented Javier.

The National College for High Speed Rail opened in 2017 with facilities in both Birmingham and Doncaster and is the first college of its kind in the UK, offering courses and apprenticeships in all elements of high-speed rail, and the broader rail and infrastructure industry.

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Routing expertise and specialist equipment overcomes challenging 1,000km delivery of wind components in ThailandDemonstrating their expertise in logistics, civils works and the complete turnkey solution, ALE has completed the transportation of heavy wind components through a challenging 1,000km route to the Rom Klao wind farm in Mukdahan, eastern Thailand.

The complete TCI solutionStarting in April 2018, ALE was contracted for the full-service package: the transportation, craneage and installation (TCI) scope of 13 wind turbines, measuring up to 5.4m in diameter and weighing up to 125t. With a hub height of 162m, these are the tallest wind turbine generators (WTGs) in South East Asia.

This project faced numerous challenges, including the sheer size and scale of the WTG components as well as the logistics and routing of components over such a vast distance, with varying obstacles and levels of infrastructure across the country that required additional civils work.

Local expertise and specialist equipmentIn order to overcome these challenges, ALE utilised their local routing and engineering expertise, and invested in specialist wind equipment, such as the unique RA4 tower clamps and the new K1650L tower crane. Manufactured specifically for the company to transport larger and heavier components, the tower clamps enabled ALE to comply with the local weight and height restrictions. Similarly, the tower crane was used as a cost and time-effective solution to install the WTGs.

“This was a complex scope of work and route to undertake. The new tower clamps enabled us to overcome the large diameters of the tower sections and reduce the travelling height to pass under the restrictions on route. Combined with the tower crane, our equipment and methodology has driven project efficiency,” explained Project Manager Matt Thomson.

“We are really pleased to have been involved in a project of this scale. It really showcased how we brought together different expertise within the Group to achieve the safe and successful completion of every stage.”

ALE completed the full TCI scope in January 2019.

Turbine erection commences for first wind power project in the Arabian GulfALE is demonstrating its wind expertise and capabilities as they undergo the final installation phase of GE wind turbine components in Oman for the Gulf Cooperation Council’s (GCC) first ever large-scale wind farm.

The global heavylifting contractor has been contracted for the Dhofar Wind Power Project, to receive, transport and install 13 wind turbine generators which consist of almost 100 large components.

Specialist transport provides efficient transportationALE started to receive the components, comprising blades, tower sections, nacelles and hubs at the Port of Duqm. Upon completion of customs clearance, all components were taken to ALE’s laydown area, close to the port, which was beneficial for the project.

The components will be transported 590km overland to the Dhofar Wind Power Project site, two components of the wind turbine generator with each convoy. Due to the sheer size and scale of the convoy, with components measuring up to 65m long and weighing up to 100t each, the items will be escorted by the police.

Utilising ALE’s specialist equipment fleet, the components will be transported using blade trailers for the blades and conventional trailers for the tower sections, nacelles and hubs.

“The client recognised our successful track record working on similar wind power projects around the world as well as our ability to work effectively with local government requirements and provide full logistical and installation solutions,” explained Shafic Tillawi, Country Manager – Oman.

“By utilising our wind-specific equipment and personnel with vital wind expertise, we can provide a timely solution with one, simplified interface.”

Expertise of dedicated ALE – Wind Services divisionOnce the transportation phase was completed, the lifting operations commenced with the support of ALE – Wind Services for the electro-mechanical installation phase. ALE has proposed a time-efficient solution by moving the main crane partially-assembled across pads with hydraulic trailers.

The project is located in the Fatkhait area of the Wilayat of Shalem and Halaniyat Islands in Oman’s southern Dhofar Governorate bordering Yemen, the largest of the Sultanate’s 11 governorates. Upon completion, the project will provide electricity to approximately 16,000 homes while displacing 110,000t of carbon dioxide emissions per year.

Sector Focus: Renewables - Wind

KR1650L crane powers wind installation packageKR1650L - the tower crane that’s opening new possibilities in project efficiency for ALE’s wind energy clients.

• Reduced civil works and reinstatement – short 70m boom and minimum lifting radius around half that of some mobile cranes mean a hardstand saving of up to 50%.

• Schedules less dependent on weather conditions – operational and out of service wind speed is higher than many other cranes.

• Lower ground loading – pedestal crane format reduces ground load requirements compared to other types of crane.

ALE adapts crane to reduce execution schedule on wind farm project in ArgentinaALE has used its innovative methods to adapt a crawler crane, Manitowoc 18000, with SPMTs to significantly reduce the schedule for the Loma Blanca wind farm project in Argentina.

Versatility overcomes narrow routeAs the project included many challenges, ALE’s experience in wind services was vital to providing the best technical and commercial solution. The dirt roads between the wind turbines are very narrow – just 6m wide in some parts – so the crane was adapted and combined with the latest SPMT transport technologies to enable the transportation. As the crane is being moved by SPMTs that are within the width limitations of the track, the crane can be easily moved on site.

To reduce the time required to disassemble and transport the crane’s components from pad to pad, the crane was initially assembled on refurbished existing beams laying on spreading mats. During the lifts, the transmitted loads were supported by the beams.

Once the rotor of the wind turbine generators had been placed, the crane was carefully set to the defined transportation parameter, being mindful of transversal inclinations. 36 axle lines of generation 3 SPMT in a 4 file 18 configuration were used to jack-up the crane. As soon as the lashing lines were tightened, the crane was manoeuvred into position for the next platform.

By utilising their extensive equipment fleet and engineering a solution so the 120m-high crane could be moved in one piece after installation, rather than disassembling crane sections and reassembling in its next lift position, this saved a huge amount of time.

Capacity increased by flexibility“The client picked ALE because of our tradition of innovation and creativity. By using in-house expertise from our Argentina branch, as well as wind experts from ALE – Wind Services, we could adapt the crane and increase our installation capacity. Equally, by choosing a different methodology to our competitors and avoiding the need to disassemble and reassemble for every

lift, we provided the most cost-effective option possible, which also reduced operational costs,” explained Andres Crespo, ALE’s Engineering Manager.

This is part of the Loma Blanca II project, where ALE has been contracted to install 16 wind turbine generators in Patagonia, Argentina.

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RECORD-BREAKING 3,400KM TRANSPORTATION, KAZAKHSTAN

CASE STUDIES AFRICA, CASPIAN AND MIDDLE EAST

CASE STUDIES AFR

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PROJECT: ALE performed the furthest and longest land transportation ever completed in Kazakhstan, deploying its specialist transport services to complete the complex 3,400km transportation of five Out of Gauge (OOG) items, each measuring up to 42m long.

The capabilities of ALE’s heavylifting and haulage equipment and their ability to draw on the support of global resources enabled ALE to transport the items using the most cost-effective method, despite the challenging terrain of the vast and complex route.

DETAILED PLANNING OVERCOMES OBSTACLES

Extensive preparations began six months in advance of the abnormal load transportation, which would move the OOG items from Bautino port to a steel plant in Termitau. ALE liaised with various local authorities to plan the most efficient route. As well as the need to survey the route and complete the engineering calculations necessary to negotiate overhead obstacles and large structures like roundabouts, over 100 bridges required inspection. The super heavy transport included items weighing up to 150t and a few bridges were found to be unsuitable for use. Where possible, bridges were reinforced but some needed to be avoided completely and ALE ensured the most cost-effective methods were utilised, building temporary side roads to bypass structures.

ALE’s scope began at the port, where they used a new 750t capacity crawler crane alongside two others to unload the items from several vessels onto waiting trailers. Drawing on their extensive equipment fleet, up to 26 axle lines of SPT were used to transport each OOG item and ALE was able to reduce costs by performing the transportation in a single convoy.

SPECIALIST TRANSPORT NEGOTIATES VAST ROUTE

The in-depth planning ensured the route could be negotiated in the most effective way possible. ALE’s specialist heavy haulage transport equipment enabled them to overcome the demanding roads on the route, which included gradients of up to 14%. The vastness of the route meant it covered both rural and urban areas so to minimise disruption ALE planned the urban sections of the journey to take place overnight.

CHALLENGING WEATHER CONDITIONS

ALE’s experience of long-term abnormal load transportation projects in a variety of climates enabled them to suitably prepare for the severe weather during the operation. Temperatures dropped to -30°, creating icy road conditions. Safety always remained at the core of the project, so conditions were monitored and the transportation was slowed down if required. To overcome the heavy snowfall and ice, ALE brought in specialist vehicles to clear the snow and applied substances to de-ice the roads.

This huge and challenging transportation of OOG items was completed over 75 days. The expertise of ALE’s team was proven in the detailed planning and preparations for the move, as well as in the execution, as they continued to battle sub-zero temperatures to complete the record-breaking heavy haulage transportation.

Watch the project here…

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RECORD-BREAKING 3,400KM TRANSPORTATION IN KAZAKHSTAN OVERCOMES SUB-ZERO TEMPERATURES TO DELIVER OUT OF GAUGE ITEMS

SECTOR: MINERALS AND METALS

KEY BENEFITS: RECORD FOR KAZAKHSTAN » COST-EFFECTIVE » MINIMISED DISRUPTION » FLEXIBLE

COMPLEX ROUTE OVERCOME TO TRANSPORT GUINEA’S LARGEST AND HEAVIEST EVER ITEMS

SECTOR: MINERALS AND METALS

KEY BENEFITS: RECORD-BREAKING TRANSPORTATION » CHALLENGING ROUTE » BESPOKE SOLUTION » MINIMISED DISRUPTION

PROJECT: Challenged with the heavy haulage transportation of fifteen mining modules, including the largest and heaviest items ever transported in Guinea, ALE needed to design a bespoke solution to overcome the route’s various obstacles.

ALE collaborated with Bolloré Logistics, who led the project, to complete the abnormal load transport from the Port of Kamsar to the new Kamsar bauxite plant in Guinea in two stages. First, three car dumper modules were unloaded using 12 axle lines of SPMT in a configuration of 4 file 6. In the second stage, 12 stacker reclaimer modules were unloaded using 24 axle lines of SPMT in a configuration of 2 x 4 file 6. For the transportation of the longest and bulkiest equipment, turn tables were used together with the SPMTs.

RECORD-BREAKING TRANSPORTATION

The record-breaking aspect of the operation came in the second stage. One of the modules, weighing 220t, was the heaviest item ever transported in Guinea, and the boom bucket, measuring 46m long and 15m wide, was the largest item ever transported in Guinea. In both cases the modules were unloaded, stored in stools in the port, and then transported to a laydown area within the plant.

BESPOKE SOLUTION OVERCOMES OBSTACLES

ALE had to overcome various obstacles on the 5km transportation route, including train tracks, two temporary bridges, turns of up to 90 degrees, and slopes with gradients of more than 7%. The biggest challenge was the existing train tracks. ALE’s solution was to design a set of link span beams. These could be assembled and disassembled quickly, which minimised the disruption to rail traffic.

While completing another record-breaking project, the experience of ALE’s team enabled them to provide bespoke equipment for the challenges of this unique operation. This efficient solution minimised disruption to the client, ensuring they were able to continue other works on the project.

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CASE STUDIES AMERICAS

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LIFTING OF A COLD BOX, USA

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PROJECT: Due to it reaching the end of its natural lifespan, the Connecticut Department of Transport (DoT) needed to replace I-95 bridgework that had stood since 1958. At the same time, it needed to ensure this crucial civil work had the minimum possible impact on local residents. Taking advantage of ALE’s expertise, two bridge superstructures, weighing 726t (800 US tons) and 817t (900 US tons), could be constructed at the roadside over a number of months, then transported the final few metres only at the time of installation. This allowed the job to be completed using just two weekend closures.

CAREFUL PLANNING

The bridges form the intersection of highway I-95 and highway 1 in Stamford, Connecticut, USA. ALE’s scope was to position both new bridge sections, following on from work by the client to demolish the old bridge sections in-situ. The bridges were built at the installation height of 7,320mm (24 ft) by the client within the infield area of the northbound onramp. During early May, ALE mobilised both its SPMT equipment and specific falsework required for the job.

To ensure the bridge girders were evenly loaded during the move, ALE imported high-capacity modular beams from its research & development centre in Europe. These were installed on top of the SPMTs, forming much of the falsework required for the job. On June 1st the first bridge installation took place, taking a total of just 6 hours. The following weekend, the second section of bridge was installed. This required reconfiguration of the falsework, as the elevations of each bridge section differed. Both bridges were approximately 24m wide and 64m long (80 x 210 ft), took the shape of a parallelogram and were installed on a slope. They also had been designed with strict support points very close to either end, further increasing the need for millimetre-accuracy in each lift.

MINIMISED DISRUPTION

Throughout the planning and execution stages of the project, ALE liaised with the Connecticut DoT, and with local third-party engineering companies to ensure all required documentation was in place. During each lift the bridges were supported by 56 axle lines of SPMT, in combination with around 280t (308 US tons) of steelwork and high-capacity modular beams. This equipment was positioned throughout the lift exactly in line with each of the structures’ two bases.

This work allowed the Connecticut DoT to restore normal traffic flow as planned – in fact, on both weekends the route was re-opened a full day ahead of schedule. The bridge is now providing a key transport link serving approximately 150,000 vehicles daily.

PROJECT: Installation of three large pressure vessels was required at a refinery in the Texas panhandle in the USA. This work needed to take place with minimal disruption to the plant’s six-figure throughput and while utilising as little space as possible. The three vessels were received on site by ALE and were each of a different size. The first was approximately 16m in length and 3.65m diameter (52ft 9in x 12ft); the second was 35m in length and 4m diameter (116ft x 13ft); the final vessel was 56m in length and 4.2m diameter (184ft x 14ft).

PRECISE POSITIONING

The smallest vessel was delivered under hook and tandem lifted by two hydraulic cranes with 100t (110 US tons) and 400t (440 US tons) capacities. This operation tailed up the vessel from its delivery trailer and set it on its foundations.

The mid-sized vessel was received by ALE in a laydown yard on site. From here, it was loaded onto SPTs fitted with bolsters and transported to its dress out location, adjacent to where it would be lifted and set in place. Once dress out was complete the vessel was weighed, establishing its centre of gravity. It was then attached by its skirt ring to an SPMT with a 450t (496 US tons) capacity tailing frame, then tailed to a vertical position and again set on its foundations. Due to its size and weight, the largest vessel was transloaded onto SPMTs using ALE’s 635t (700 US tons) capacity gantry lifting system. It was then transported to the dress out location, where it was rotated 60 degrees, having been shipped out of orientation. This rotation was performed using chain hoists in combination with the above gantry lifting system.

The final vessel was then tailed up in similar fashion, using a tailing frame mounted to an SPMT and a 1,350t (1,488 US tons) capacity crawler crane, with 84m (275ft) main boom configuration and a 560t (617 US tons) counterweight. The radius of all tailing lifts was 38m (125ft).

Equipment used during these lifts included 40 axle lines of SPMT, ALE’s Lift ‘N’ Lock gantry lifting system, 300t (330 US tons) capacity weightors, plus various pieces of staging equipment. The project also utilised LTM 1100 and 1400 mobile cranes and an LR11350 mobile crane.

MAXIMUM UPTIME

The project allowed refinery activity to continue during installation. In particular, ALE’s custom transportation methodology for the largest of the three vessels ensured installation could take place without shutdown or rerouting of a large pipe rack on site. The methodology used for all vessels also minimised working at height, as dressing out could take place at ground level prior to lifting. All three vessels will shortly be used to increase petroleum processing capability at the plant.

DISRUPTION REDUCED DURING BRIDGE INSTALLATIONS OVER I-95 HIGHWAY, USA

SECTOR: CIVIL

KEY BENEFITS: REDUCED IMPACT TO POPULATION » SUPPORTED OFF-SITE CONSTRUCTION » CUSTOM LIFT REQUIREMENTS MET

PRECISE LIFTING ENABLES SMOOTH REFINERY EXPANSION, USA

SECTOR: OIL AND GAS

KEY BENEFITS: UPGRADE PERFORMED WITHOUT SHUTDOWN » ALL-IN-ONE RECEIPT AND » INSTALLATION » LIFT OPTIMISED FOR SAFETY

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CASE STUDIES AUSTRALASIA AND ASIA PACIFIC

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SAFETY COMES FIRST IN HEAVY TRANSPORT AND LIFTING PROJECT IN SINGAPORE

SECTOR: SHIPYARDS

KEY BENEFITS: REDUCED RISK » IN-HOUSE EXPERTISE » HIGH TRAINING LEVELS

COMPLETE WIND SERVICES PACKAGE SHOWCASED AT WILLOGOLECHE WIND FARM, AUSTRALIA

SECTOR: RENEWABLES – WIND

KEY BENEFITS: FULL TCI PACKAGE » SPECIALIST WIND EQUIPMENT

PROJECT: ALE showcased its full wind service expertise when executing the heavy transport and installation operations for the Willogoleche Wind Farm in South Australia.

COMPLETE TCI PACKAGE

ALE was contracted for the complete scope of work, including the receiving, port handling, transportation, crane lifting and electromechanical installation of 32 wind turbine generators.

The components started to arrive and were offloaded at the Port of Adelaide in March and put into storage. ALE was responsible for project managing and delivering these to the wind farm site on Willogoleche Hill, 160km north of Adelaide.

SPECIALIST WIND EQUIPMENT

ALE invested in specialist wind equipment, including blade and low bed trailers suited to carry these wind components. Their highly trained and experienced installation team performed the mechanical and electrical works.

Paul Kelly, Director – Australia, said, “Our dedicated ALE – Wind Services division has been deployed to work alongside our local teams to complete this specialised scope of work. From port handling and heavy transport to the complex installation activities, we have the knowledge and equipment to manage the whole package for the client. The successful execution to date and safe teamwork really demonstrates our capabilities in the wind market.”

MECHANICAL AND ELECTRICAL INSTALLATION OF WIND COMPONENTS, AUSTRALIA

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PROJECT: ALE’s operational expertise and focus on safety has been demonstrated during the heavy transportation and lifting operations of an FPSO project in Singapore.

ALE was tasked with transporting, lifting and installing eight modules, weighing up to 1,820t, onto an FPSO for the Liza Destiny FPSO project. For the transportation, ALE utilised 72 axle lines of SPMT to move the modules from the fabrication yard to the quayside.

Once at the quay, an offshore crane was used to lift and install these modules onto the vessel.

EXCEPTIONAL FPSO SAFETY PERFORMANCE

The team’s proactive approach to safety was recognised with the ‘Best Safe Supervisor Award’ granted by the client.

The operational team of six were praised by the client: “Your willingness to step up and go beyond your responsibilities is highly commendable. Thank you for your continual dedication to safety.”

“It was the first time we worked with this particular client and they had confidence in our abilities from our proven track record in the region,” explained Roberto Radicella, General Manager for ALE’s Malaysia branch.

EXPERTISE DELIVERS QUALITY CAPABILITIES

“The client has recognised our professionalism and skill. We have a huge focus on in-house training and ensuring our operators have internationally-consistent standards of regular training as well as a proactive focus on safety excellence so we can deliver the highest level of quality on site. The fact that we only required six operators to undertake this project, less than half the crew other companies have previously deployed, is a good indicator of the expertise and capability we have within the team.”

The project was completed within one month. Once the FPSO build is complete, the FPSO will be located 190km offshore in the Liza Field and is expected to produce up to 120,000 barrels of oil per day. The FPSO facility will develop approximately 450 million barrels of oil from Liza Field.

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CASE STUDIES EUROPE

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PROJECT: ALE has negotiated steep gradients, bridges and other challenges to complete the transportation of two transformers. From the port of Inverness, the transformers, weighing 193t each, were transported along a complex route to Tomatin Substation in Scotland, UK, where they were successfully installed.

The transportation was performed using ALE’s AL34 girder frame with 24 axle lines of conventional trailer, two Trojan trucks and an additional prime mover. There were numerous structures on the route, including three onsite bridges, and ALE selected this equipment to reduce the axle loadings, enabling safe transportation over them all.

INNOVATIVE CIVIL ENGINEERING

All the bridges were assessed during the planning stages to ensure they could support the transport loads. However, the capacity of one bridge could not be sufficiently determined and therefore an efficient alternative had to be found. ALE’s creative solution was the installation of an overbridge. A crane needed to be positioned a suitable distance from the centre of the bridge, so ALE utilised a 100t capacity mobile crane to install the 12m bridge raft over the bridge’s 9m span.

Another challenge on the route was the range of steep gradients, both up and downhill, that the convoy needed to negotiate. ALE transported the transformers over gradients of up to 14% and this was further complicated by road surfaces made up of loose materials. It was an opportunity for the Trojan trucks to demonstrate the strength of their capacities as they operated at their maximum gradient.

VERSATILE TROJAN TRUCKS

As there is no limit to the number of prime movers that can be added to a convoy with the Trojans, ALE was able to further utilise the capabilities of the innovative trucks by adding a third prime mover for the transportation through Farr Wind Farm. This route between the public highway and the substation spanned almost 18km and its constant bends and varying gradients made it the most complex part of the transportation. On the Trojan trucks, steering, braking, electrics, engine, and transmissions are synchronised by a computer, enabling each to be matched across the vehicles and numerous elements to be controlled identically. This made them the most efficient vehicles to assist with traction during this section of the transportation.

ALE transported the transformers over 35km before installing them at the substation with the operation being completed in 12 days. ALE’s innovative solutions and the unique abilities of the Trojan truck ensured that this challenging operation could be completed as efficiently as possible.

PROJECT: ALE’s precision and accuracy has enabled them to perform the swift relocation of an entire house, weighing 650t, in Alphen aan den Rijn, Netherlands.

The structure of the house meant a very accurate lifting method was needed as well as a considerable amount of additional steel to strengthen the house and provide the structural integrity required for the specialist transportation. ALE also looked for a method to complete the move as efficiently as possible to minimise disruption to the local area and enable other construction operations to continue.

ACCURATE JACKING METHOD

Early involvement in the planning processes enabled ALE to develop effective communication with the client for a smoother operation, which used jacking techniques and SPMTs for the heavy haulage transportation of the house.

The house had already been detached from its foundations and ALE first positioned 700 bar jacks, so that the weight of the house could be transferred onto them from concrete posts. 29 climbing jacks were installed in groups of 12 underneath the concrete posts. Each group was pre-loaded to reduce deflections for greater exactitude, before ALE jacked-up the house by 2.5m. The climbing jacks were then relocated to make space for the SPMTs.

SAFER STABILITY SUPPORT

A steel structure was created to support the house and spread the load evenly during the abnormal load transportation. ALE then transported the house 100m using 30 axle lines of SPMT.

ALE’s specially-tailored method ensured the house relocation could take place as swiftly and safely as possible. The house was relocated so that a new building could be constructed in its place.

Watch the project here…

COMPLEX TRANSPORTATION OF TWO TRANSFORMERS, UK

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CHALLENGING ROUTE COMPLETED WITH INNOVATIVE BRIDGE ENGINEERING AND TROJAN TRUCKS, UK

SECTOR: POWER GENERATION

KEY BENEFITS: COMPLEX ROUTE » INNOVATIVE EQUIPMENT » INCREASED SAFETY » IN-HOUSE LOGISTICS EXPERTISE

PRECISE JACKING AND TRANSPORTATION ENSURE SWIFT RELOCATION OF ENTIRE HOUSE IN THE NETHERLANDS

SECTOR: CIVIL

KEY BENEFITS: MINIMISED DISRUPTION » SWIFT OPERATION » THIRD PARTY CO-ORDINATION

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