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5/28/2018 30973377 RTG Site Assembly R1
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Rubber Tyred Gantry Crane - Site Assembly Procedure
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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
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Gantry Assembly
Trolley & Hoist
Assembly
Head Block
Assembly
Cabin
Spreader
Resistor Platform
& Resistors
Cable Chain
Festoon System
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LEG
Bridge Girder
Walkway
Access Way
Diesel
Generator
E-Room
Tie Rod
Diesel Generator
Sliding and
Folding Access
Platform
Exhaust
System
Sill Beam
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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
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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
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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
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Picture 4
Exhaust Pipe
Walkway Gratings
Cable Trays & Cables Installed
Coating System applied
after welding
Crane SignsApplied
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At the same time the Structural Assembly is being prepared the Lower Sill Beam
and Gantry is assembled and aligned.
First item of this works is to Assemble the Equalizer Beam / Wheel Fork Assembly
to the Sill Beam with the Pin Connection (NCSC will Supply the Equalizer Beam /
Wheel Fork Assembly ). Picture 5 (Next Slide) shows the completed assembly.
Picture 5 The following is the preparation procedure for the Sill Beam Assembly
to accept the Upper Portal Assembly Connection:
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.
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Backing Strip
Level Support Stands
Equalizer /
Wheel Fork
AssemblyCounter Weight Blocks
Picture 5
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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.
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Lifting Frames
150T
Crawler
Crane
Lifting SpreaderBeam
Tie
Rods
Picture 6
Welding
Process
Cables From Upper Portal to
Counterweight Blocks
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Rail Distance
Picture 7
Tie Rod
Connection
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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
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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
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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)
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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
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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
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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
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Picture 20 After all Structural /
Mechanical / Electrical works
(confirmed by Q.C.) the RTG Crane is
Hand Over to the Commissioning
Team.
Picture 21 RTG Cranes ready for
Shipment and loading to Barge
Picture 20
Picture 21