30973377 RTG Site Assembly R1

5/28/2018 30973377 RTG Site Assembly R1

1/20

Rubber Tyred Gantry Crane - Site Assembly Procedure


2/20

Rubber Tyred Gantry Crane Site Assembly - Man Power Description

Structural Works

1. Fabricators Fabricators for Structural Plate Cutting and Plate Edge Weld

Preparation.

- Fabricators for General Works.

2. Welders Welders Pre-Qualified (6G Position) M.A.W. Welding Process Full

Penetration One (1) Side.

- Welders for General Works.

Mechanical

1. Mechanical Mechanics for Detailed Assembly, Gantry Drives, Mechanical

Systems.

2. Mechanical Mechanics for Basic works including Assembly of Ladders, Access

Ways, Wheel Guards,etc.

Electrical

1. Electrical Electricians Pre-Qualified for Final Termination Works.2. Electrical Electricians 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


3/20

Gantry Assembly

Trolley & Hoist

Assembly

Head Block

Assembly

Cabin

Spreader

Resistor Platform

& Resistors

Cable Chain

Festoon System


4/20

LEG

Bridge Girder

Walkway

Access Way

Diesel

Generator

E-Room

Tie Rod

Diesel Generator

Sliding and

Folding Access

Platform

Exhaust

System

Sill Beam


5/20

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 Support

Stands


6/20

6

After the welding process is completed,

the Weld Joint and surrounding area

must be Painted with the CoatingSpecification As per ISO 8501-1 and

by mechanical power tool cleaning.

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

Picture 3


7/20

After the Structural (Fabrication / Welding / Coating of the Welded Joints) the following items can

be completed.

Picture 4 (next Slide)

1. Cable Tray Installation

2. Cable Installation

3. Cable Tray Covers Installation

4. Generator Exhaust Pipe Installation

5. Walkway Grating Installed

6. Crane Signs Painted (These signs are painted where the Lifting Arrangement will not damage theSigns. 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 Light

Installation


8/20

Picture 4

Exhaust Pipe

Walkway Gratings

Cable Trays & Cables Installed

Coating System applied

after welding

Crane SignsApplied


9/20

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:

1. 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.

2. 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

3. 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)

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


10/20

Backing Strip

Level Support Stands

Equalizer /

Wheel Fork

AssemblyCounter Weight Blocks

Picture 5


11/20

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 completedwith the N.D.T. 100% U.T. Inspection.

After the welding process is completed, the Weld Joint and surrounding area mustbe 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.


12/20

Lifting Frames

150T

Crawler

Crane

Lifting SpreaderBeam

Tie

Rods

Picture 6

Welding

Process

Cables From Upper Portal to

Counterweight Blocks


13/20

Rail Distance

Picture 7

Tie Rod

Connection


14/20

Picture 8

1. Generator Installation weight 10T

2. Generator Access Platforms Installation

3. Sill Beam Cable Tray Installation4. Electrical Junction Box Installation

5. Electrical Cable Installation and

Termination

Picture 9

1. E-Room Installation weight 8T

2. E-Room Access Platforms Installation

3. Sill Beam Cable Tray Installation

4. Electrical Junction Box Installation

5. Electrical Cable Installation and

Termination.

Picture 8

Picture 9


15/20

Picture 10

1. Install Resistor Bank Platform and

Resistors

2. Install Access Ways and LightingSystems

Picture 11

1. Install Gantry Drive Assemblies

(Electric or Chain Drive)

2. Install Wheel Turning and Locking

Assemblies

3. Install Diesel Fule Tank Systems

4. Picture 12 (next page) shows Wheel

Assemblies which will be supplied by

NCSC to be installed.

Picture 10

Picture 11


16/20

Picture 12 - Wheel Assemblies which

will be supplied by NCSC

Picture 12 (a) Install Wheel Guards

and Gantry Drive Protections (noted

with red arrows)

Picture 12

Picture 12 (a)


17/20

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 the

lifted onto the Crane Upper Structureand the Final Electrical / Mechanicalworks can be completed weight 27Tusing the 150T Crawler Crane.

Picture 13

Picture 14


18/20

Picture 15 & 16 Cable Track & Chain

Festoon System installed and

Electrical Termination workscompleted.

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


19/20

Picture 17 Install Head Block

Assembly (supplied by NCSC) and

Reeve Main Hoist and Anti-Sway Rope

System.

Pictures 18 & 19 Typical Cable Tray,

Junction Box and Intercom Installation

works.

Picture 17

Picture 18 Picture 19


20/20

Picture 20 After all Structural /

Mechanical / Electrical works

(confirmed by Q.C.) the RTG Crane is

Hand Over to the Commissioning

Team.

Picture 21 RTG Cranes ready for

Shipment and loading to Barge

Picture 20

Picture 21

30973377 RTG Site Assembly R1

Documents

Transcript of 30973377 RTG Site Assembly R1