Rubber Tyred Gantry Crane - Site Assembly Procedure

Rubber Tyred Gantry Crane Site Assembly - Man Power Description

• Structural Works1. Fabricators – Fabricator’s for Structural Plate Cutting and Plate Edge Weld

Preparation.- Fabricator’s for General Works.

2. Welder’s – Welder’s Pre-Qualified (6G Position) M.A.W. Welding Process – FullPenetration One (1) Side.

- Welder’s for General Works.• Mechanical1. Mechanical – Mechanic’s for Detailed Assembly, Gantry Drives, Mechanical

Systems.2. Mechanical – Mechanic’s for Basic works including Assembly of Ladders, Access

Ways, Wheel Guards,etc.• Electrical1. Electrical – Electrician’s Pre-Qualified for Final Termination Works.2. 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 RTGCrane

Gantry Assembly

Trolley & HoistAssembly

Head BlockAssembly

Cabin

Spreader

Resistor Platform& Resistors

Cable ChainFestoon System

LEG

Bridge Girder

Walkway

Access Way

DieselGenerator

E-Room

Tie Rod

Diesel GeneratorSliding andFolding AccessPlatform

ExhaustSystem

Sill Beam

• Picture 1 – Lay out Bridge Girder andLeg Structures and Level – Align.

• A qualified Structural Surveyor with aLevel Instrument and Theodolyte isrequired.

• Measure the Structures and confirmAlignments and Measure the LegStructure to be Cut / Trimmed for theconnection to the Bridge Girder.

• Picture 2 - Cut / Trim / EdgePreparation of the Leg Structure Jointto the Bridge Girder. Note that theWeld Joint Design is Full Penetrationfrom one (1) Side with Backing Strip.

• After Preparation – Tack up• Structural Surveyor with a Level

Instrument and Theodolyte to ConfirmAlignments and Measurements.

• Full Penetration Weld Process• Q.C. NDT – U.T. 100%

Picture 1

Picture 2

Weld Joint

Structure SupportStands

6

• After the welding process is completed,the Weld Joint and surrounding areamust be Painted with the CoatingSpecification As per ISO 8501-1 andby mechanical power tool cleaning.

• Picture 3 – The Leg Connection to theSill Beams must be prepared.

• Measurement Joint Preparation and• Structural Surveyor with a Level

Instrument and Theodolyte to ConfirmAlignments and Measurements.

• Note that the Weld Joint Design is FullPenetration from one (1) Side withBacking Strip

Picture 3

• After the Structural (Fabrication / Welding / Coating of the Welded Joints) the following items canbe completed.

• Picture 4 (next Slide) –1. Cable Tray Installation2. Cable Installation3. Cable Tray Covers Installation4. Generator Exhaust Pipe Installation5. Walkway Grating Installed6. 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)7. Portal (Bridge Girder) Flood Light Installation including cabling (Photo Below)8. Final Paint Touch –Up where damage has occurred during installation works

Flood LightInstallation

Picture 4

Exhaust Pipe

Walkway Gratings

Cable Trays & Cables Installed

Coating System appliedafter welding

Crane SignsApplied

• At the same time the Structural Assembly is being prepared the Lower Sill Beamand Gantry is assembled and aligned.

• First item of this works is to Assemble the Equalizer Beam / Wheel Fork Assemblyto 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 Assemblyto accept the Upper Portal Assembly Connection:

1. Install Sill Beam / Gantry Assembly to Leveled Support Stands. Again the processmust be done with qualified Structural Surveyor with a Level Instrument andTheodolyte to Confirm Alignments and Measurements.

2. The two (2) Sill Beam Assemblies (Diesel Side & E-Room Side) must be alignedcentrally and together with the Four (4) corners of the Structure Leveled andAligned

3. The Sill Beam Assemblies and also tied with Counter Weight Blocks for Safetyduring the Pre-Assembly and Assembly of the Upper Portal Structure (two (2)Counterweights per side – each Counterweight 10Tons)

4. Backing Strip installed at the Four (4) Upper Portal Connection Areas.

Backing Strip

Level Support Stands

Equalizer /Wheel ForkAssembly Counter Weight Blocks

Picture 5

• Picture 6 (Next Slide) – The Upper Portal Assembly - weight includind AccessWays, Cable Trays and Cables = 31Ton ( 1 Bridge Girder & 2 Legs ) is lifted intoposition using the Following Lifting Arrangement (Note also the pre-installation ofthe Tie Rods) –

1. 1 x Lifting Spreader Beam – 5T.2. 2 x Lifting Beams - 0.75T ea x 2 = 1.5T.3. 2 x Lifting Wire Rope Sling Arrangements ( Each Sling Arrangement Capacity 35T).4. 1 x 150 T Crawler Crane.5. 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 qualifiedStructural 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 mechanicalpower tool cleaning.

• Picture 7 (2nd Next Slide) – After the Two (2) Upper Portal Assembles areinstalled the Rail Distance (Shown by the Red Arrow) must be confirmed and thenthe Tie Rods between the two (2) Assemblies may be connected.

Lifting Frames

150TCrawlerCrane

Lifting – SpreaderBeam

TieRods

Picture 6

WeldingProcess

Cables From Upper Portal toCounterweight Blocks

Rail Distance

Picture 7

Tie RodConnection

• Picture 8 –1. Generator Installation – weight 10T2. Generator Access Platforms Installation3. Sill Beam Cable Tray Installation4. Electrical Junction Box Installation5. Electrical Cable Installation and

Termination

• Picture 9 –1. E-Room Installation – weight 8T2. E-Room Access Platforms Installation3. Sill Beam Cable Tray Installation4. Electrical Junction Box Installation5. Electrical Cable Installation and

Termination.

Picture 8

Picture 9

• Picture 10 –1. Install Resistor Bank Platform and

Resistors2. Install Access Ways and Lighting

Systems

• Picture 11 –1. Install Gantry Drive Assemblies

(Electric or Chain Drive)2. Install Wheel Turning and Locking

Assemblies3. Install Diesel Fule Tank Systems4. Picture 12 (next page) shows Wheel

Assemblies which will be supplied byNCSC – to be installed.

Picture 10

Picture 11

• Picture 12 - Wheel Assemblies whichwill be supplied by NCSC

• Picture 12 (a) – Install Wheel Guardsand Gantry Drive Protections (notedwith red arrows)

Picture 12

Picture 12 (a)

• Picture 13 – Cabin Assembly –Supplied by NCSC.

• Picture 14 - Cabin to TrolleyInstallation. The Electrical TerminationWorks from the Cabin to the TrolleyJunction Box can be completed at thephase.

• The complete Trolley Assembly is thelifted onto the Crane Upper Structureand the Final Electrical / Mechanicalworks can be completed – weight 27Tusing the 150T Crawler Crane.

Picture 13

Picture 14

• Picture 15 & 16 – Cable Track & ChainFestoon System installed andElectrical Termination workscompleted.

• Note – After all the ElectricalTermination Works are completed aComplete Line Check to be done andthe Wiring Diagram is marked up asconfirmation.

Picture 15

Picture 16

• Picture 17 – Install Head BlockAssembly (supplied by NCSC) andReeve Main Hoist and Anti-Sway RopeSystem.

• Pictures 18 & 19 – Typical Cable Tray,Junction Box and Intercom Installationworks.

Picture 17

Picture 18 Picture 19

• Picture 20 – After all Structural /Mechanical / Electrical works(confirmed by Q.C.) the RTG Crane isHand Over to the CommissioningTeam.

• Picture 21 – RTG Cranes ready forShipment and loading to Barge

Picture 20

Picture 21