South Helwan Supercritical Power Plant

3x650 MW Gas Oil Fired Units

Auxiliary Boiler Critical lifts

Unloading, Shifting, Rotating and Erection

3
2
1
REV.

22/9/2016
DATE

MEC
ORIGINATOR

MEC
REVIEWED

MEC HO
APPD

ACB
APPD

PGESCO
DESCRIPTIO
N

ORIGINATOR: MEC

TABLE OF CONTENTS
1.0 SCOPE
2.0 PURPOSE
3.0 DEFINITION
4.0 REFERENCE DOCUMENTS
5.0 RESPONSIBILITIES
6.0 SEQUENCE OF WORK
7. RESOURCES
8. HEALTH, SAFETY & ENVIRONMENT

1.0 SCOPE
This Auxiliary Boiler Critical Lifts Unloading, Rotating and Erection Working Procedure is prepared in
full compliance with the ACB specifications and other ACB documents and shall not after modify or
adjust any of the requirements unless specifically agreed per ACB.
The scope of this Auxiliary Boiler Critical lifts Unloading, Rotating and Erection working procedure is to
provide the detailed description of lifting plan.

2.0 PURPOSE
The purpose of this lifting plan is to set the safe methodology for Auxiliary Boiler Critical Lifts Unloading,
Rotating and Erection Working Procedure to be followed during execution in South Helwan
Supercritical Power Plant.

3.0 DEFINITION
The following definitions are applied:
3.1

ACB

AC-Boiler

3.2

MEC

Mariout Engineering and Construction

3.3

PROJECT

South Helwan Supercritical Power Plant

4.0 REFERENCE DOCUMENTS

4.1

AUX-Boiler-Erection procedure boiler in site assembling Doc. No. 30600-D-G4847 Rev.0.

4.2 Boiler lifting drawing 15EB0201-M-910 rev-2 date 06-06-16.

4.3 Boiler shipping assembly 15EB0201-M-900 rev-0 date 05-11-15
4.4 Transport base frame assembly and details 15EB0201-M-500 rev. 1 date 25-11-15.

5.0 RESPONSIBILITIES
MECS Site Manager shall be responsible for overall Auxiliary Boiler Critical Lifts Unloading, Rotating
and Erection activities, ensure that all pre-construction formalities, approvals and preparation are done
sufficiently in advance to start the construction activity as per the schedule.
MECS HSE Manager shall be responsible for overall Auxiliary Boiler Critical Lifts Unloading, Rotating
and Erection safe operation, ensuring that all safety measures are implemented and HSE formalities,
approvals and preparation are done sufficiently in advance to start the construction activity as per the
HSE roles.
MECS Q.C. Manager shall be responsible for overall Auxiliary Boiler Critical Lifts Unloading, Rotating
and Erection quality control, formalities, approvals and preparation are done sufficiently in advance to
start the construction activity.
MECS Engineer (Mechanical) shall be responsible for actual performance of work directly at site,
Coordination with other departments, receiving material from store, storing at site, Handling,
Traceability, installation all in accordance with approved specification and drawings by obtaining Work
permit from relevant authorities.
MECS Q.C Engineer shall be responsible for welding in accordance with approved WPS, specification
by assigning qualified welders for welding works, welding consumable control, and to ensure correct
consumables are being used and preparation/compilation of QC records and reports.
MECS Safety officer shall be responsible for the conduct of safe working practice as per ACB/MECs
procedure and ensure that all activities are performed by strictly adhering to safe working practice and
Permit to work procedure.

6.0 SEQUENCE OF WORK

6.1 Pre-Commencement Works:
Work Permit
Work permit shall be obtained prior to commencing of any activity and retained at site during the
works.

Ground will be checked before lifting operation. If necessary, ground will be compacted or
tested. The ground must be firm enough to prevent the crane from sinking and to protect the
existing foundation and anchor bolts.

6.2 Unloading, shifting and rotation Operation:

6.2.1 Load description:
LOAD DETAILS

Quantity

Weight
/
Weight
Each (ton)
(ton)
100
100

1. Total load(weight of actual items to be lift)

1
2. Rigging Bill of materials:
5
5
Sling wire
Shackles
Spider beam
Cranes hook block
Total weight
105
During unloading, shifting and rotation two crane is going to work so the load is
applying for each one is 52.5 ton.
6.2.2 Crane Location and Unloading Radius:
As per underneath sketch:
Main crane radius is 12.5 mt approximately
Tail crane radius is 7 mt approximately

6.2.3 Main Crane and Tail Crane Capacity:

Main Crane: LTM1500
Main Crane capacity of 12.5 mt radius and boom length 31.7 mt during unloading, shifting and
rotation is 111 ton therefore the maximum % of capacity used is 52.5/111= 47 %

Tail Crane : LTM1200

Tail Crane capacity of 7 mt radius and boom length 31.3 mt during unloading, shifting and
rotation is 80 ton therefore the maximum % of capacity used is 105 x 65 % ( 68 )/80= 85 %

6.2.4 :Tension Wire Analysis during Unloading shifting and rotation only
Main Crane MLT 1500 / two wires 3 X 8 mt length
As per Drawing No. 15EB021-M-500 Lugs distance is 7200mm

Load weights =105/2 =52.5 Ton.

No.2 steel sling wire 3 X 8 mt X 66 Ton.
Connected each one by shackle 85 Ton.
Each wire load = 66 Ton as per SWL of slings at 60 degree

Total weight all items = 52.5 Ton.

Share of Load (SOL) =Weight /No. wire =52.5/2= 26.25 Ton For each wire
Load Angle factor (LAF) = 8/7.144 =1.12
Tension in wire = LAF X SOL = 1.12 X 26.25 = 29 Ton
% each wire capacity = wire tension / wire load = 29/66 X 100 = 44 %

Tail Crane MLT 1200 / two wires 2.5 X 8 mt length and two wires 2.5 X 6mt + spider beam

As per Drawing No. 15EB021-M-500 Lugs distance is 9000 mm

Load weights =65 % of total weight at worst case = 65*105/100 = 68.25 Ton.
No.2 steel sling wire 2.5 X 8 mt X 47 Ton. And Connected each one by shackle 85 Ton.
Each wire load = 47 Ton as per SWL tables on 60 degree.

Total weight all items at worst case = 68.25 Ton.

Share of Load (SOL) =Weight /No. wire =68.25 /2= 34.13 Ton For each wire
Load Angle factor (LAF) = 8/6.6=1.2
Tension in wire = LAF*SOL = 1.2 X 34.12 = 41 Ton
% each wire capacity = wire tension / wire load = 41 /47 X 100 = 87 %

No.2 steel sling wire 2.5 X 6 mt X 54 Ton. And Connected each one by shackle 68.25 Ton.
Each wire load = 54 Ton.

Total weight all items at worst case = 68.25 Ton.

Share of Load (SOL) =Weight /No. wire =68.25 / 2= 34.13 Ton For each wire
Load Angle factor (LAF) = 1 due to 90 degree
Tension in wire = LAF*SOL =1 X 34.13 = 26.25 Ton
% each wire capacity = wire tension / wire load = 34.13 /54 X 100 = 63 %

6.3 Erection Operation:

6.3.1 Load description:
LOAD DETAILS

Quantity

Weight

Weight

Each (ton)
100

(ton)
100
-8.8

2. Total load(weight of actual items to be lift)

1
Transportation frame should be remove from boiler
weight (8800 Kg )
2. Rigging Bill of materials:
5
5
Sling wire
Shackles
Spider beam
Cranes hook block
Total weight
96.2
During erection only main crane is going to work along so the load is applying 96 ton.
6.3.2 Crane Location and Erection Radius:
As per underneath sketch:
Main crane radius is 13 mt approximately

6.3.3 Main Crane Capacity:

Main Crane: LTM1500
Main Crane capacity of 13 mt radius and boom length 26.5 mt during Erection is 113 ton
Therefore the maximum % of capacity used is 96 /113= 85 %

6.3.4 :Tension Wire Analysis during Erection

Main Crane MLT 1500 / two wires 3 X 8 mt length
As per Drawing No. 15EB021-M-500 Lugs distance is 7200mm

Load weights =96 Ton.

No.2 steel sling wire 3 X 8 mt X 66 Ton. as per SWL tables on 60 degree
Connected each one by shackle 85 Ton.
Each wire load = 66 Ton. as per SWL tables on 60 degree

Total weight all items = 96 Ton.

Share of Load (SOL) =Weight /No. wire =96/2= 48 Ton For each wire
Load Angle factor (LAF) = 8/7.1=1.13

Tension in wire = LAF X SOL = 1.13 X 48 = 54 Ton

% each wire capacity = wire tension / wire load = 54/66 X 100 = 81%

7.0 RESOURCES
Resources shall be mobilized as required to ensure that the work is carried out as per schedule and in a safe
manner

8.0 HEALTH, SAFETY & ENVIRONMENT

All personnel involved in the above activities shall follow the requirements of HSE Plan
All safety measures and ACB safety procedures shall be implemented.
All operators shall have valid license from EGYPT.
Prior to commencement of works Task Risk Assessment (TRA) shall be prepared, workers shall be taken
through all the risks involved.
Tool box talk shall be carried out by HSE manager.
Crane Daily check will be done by the crane operator using the inspection check list.
Adequate safe lifting capacity of the crane is to be confirmed from the load charts, before the start of the
respective work.
Ground will be checked before lifting operation. If necessary, ground will be compacted or tested. The
ground must be firm enough to prevent the crane from sinking.
Barricades will be erected around the work and signs posted to clearly define the work area.
Lifting will be suspended if wind speed is more than HSE requirements or crane manufacturers
recommendations.
All lifting and rigging equipment to be used will be in good condition and be 3 rd party certified and colorcoded.
All slings and shackles will be checked before any lifting operation. If any damage is noticed they will be
reported directly to HSE Department and be disposed of to prevent future use. Slings shall be protected
from any sharp edges of the load by using softeners.
When working at height outside of certified platforms, all employees shall wear double lanyard full body
harnesses with 100% tie-off. All workers must be trained for fall protection or working at height.
Tag lines will be fixed to control the load during lifting operations. Minimum of 2 tag lines shall be used.
No one will be allowed to stand under the suspended load.
Only certified signal men will conduct lifting operations. Certified riggers.
Work will be carried out in accordance with the MS, PTW, and TRA.
Hand tools, bolts, nuts, etc; shall not be pitched or thrown from height by any person. Bolt carrying bags
shall be used.
Proper housekeeping shall be maintained.