LIFTING LETTER - Barnhart Crane & Rigging · The project was performed during an outage schedule so work was performed 24/7 while abiding by MSHA safety rules. With precise engineering

Vol. 63 2019 | www.barnhartcrane.com 1VOL. 63Copyright 2019A Publication of Barnhart

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6 16NUCLEAR: CRANE LOAD TESTS

MINIMoCCs

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18BRANCHPROFILE: Columbus, MS

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www.barnhartcrane.com

LIFTINGLETTER

CARING FOR OUR COMMUNITIES

Vol. 63 2019 | www.barnhartcrane.com2

TABLE OF CONTENTSCARING FOR OUR COMMUNITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CHEMICAL : REACTOR REMOVE AND REPLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

REF INERY: REGEN & REACTOR HEAD REMOVAL & REPLACEMENT . . . . . . . . . . . . . 5

NUCLEAR : CRANE LOAD TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

POWER : TRANSFORMER TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

NUCLEAR : REACTOR REMOVAL AND TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DEPARTMENT OF ENERGY: ACCELERATOR VESSEL LOAD OUT . . . . . . . . . . . . . . . . . . 9

MANUFACTUR ING : BALL M ILL REMOVAL AND REPLACEMENT . . . . . . . . . . . . . . . . 10

POWER : STATOR L I FT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

POWER : E LECTR ICAL SHELTER HAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

POWER : TURB INE AND TURB INE GENERATOR REMOVE AND REPLACE . . . . . . 13

MANUFACTUR ING : BO I LER INSTALLAT ION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

NUCLEAR : ROTOR REMOVAL AND HAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

BRANCH PROF I LE : COLUMBUS , MS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

EQU IPMENT PROF I LE : M IN I MOCCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18TABL

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Members of the Phoenix branch packed 7,776 Manna meals for Feed My Starving Children, which are donated to FMSC food partners around the world.

Two team members from the Mount Vernon, Washington, branch refurbished a donated miniature tower crane, which is a popular interactive exhibit at The Children’s Museum of Skagit County.

Vol. 63 2019 | www.barnhartcrane.com 3

Barnhart is passionately committed to investing in all of the

communities in which we are located—all 45 of them. We

strive to make it easy for our employees to get involved in the

local causes that matter the most to them and their families.

In addition to giving each employee $25 per month to give

to the ministry or charity of their choice, for every hour

volunteered, Barnhart matches it at $50/hour, up to 10 hours

per quarter. We also have Barnhart Community Cares grants

to help the underserved in our communities ranging from

first-year grants of $1,000 to $5,000 in year five.

Over 60% of Barnhart employees give back in a variety of

ways. Here are some recent examples:

• Barnhart’s Houston team collected a trailer’s worth of

school supplies to donate to a local elementary school.

• The Long Beach branch participated in the Whittier Area

Community Church’s “Welcome Home” Event, which

provides families transitioning out of homelessness with

items to create a warm and functional home.

• Members of the Monroe, Michigan branch volunteered

at the 10th Annual Forget-Me-Not 5K to benefit CASA of

Monroe County, a program that trains adult volunteers

to serve as Court Appointed Special Advocates (CASAs)

for children.

Whatever the activity, our volunteers have learned that

when you give of yourself to others, you get so much more

back in return!

CARING FOR OUR COMMUNITIES

COVER STORY

Members of our Houston branch served the homeless at the Loaves & Fishes soup kitchen.

Representatives from Barnhart’s Ladd, Illinois, branch presented a $1,000 donation to the Second Story Teen Center in Princeton. Second Story provides services to at-risk youth. Photo credit: Jim Dunn, Bureau County Republican.

A Harvest for Hunger representative from the Akron-Canton Regional Foodbank presented the Canton, Ohio branch with a plaque in recognition of their donations.


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The new reactor arrived early so it was loaded and staged

on a Barnhart trailer while the team was building the

Liebherr LTM 1400 mobile crane. It was staged onsite so it could

be moved into position when ready. This was done to save the

customer money, as offloading in the laydown yard would require

remobilizing a crane and truck.

The 500-ton mobile crane had 86’ of main boom with

125’ of luffing jib and 275,500 pounds of counterweight.

The reactor weighed 43,000 pounds at 135 ft. radius for the

lift. The team navigated pipe racks and powerlines and faced

windy conditions.

The scope of work was to be completed in five days

from mobilizing and building the crane, completing all

lifts, putting the roof cover in place and demobilizing. The job was

completed on schedule and safely.

Barnhart was hired to remove and replace a reactor at

a chemical plant. The reactor was 11’ diameter and 20’

long and the only access was through the roof, so the customer

fabricated a 14’ X 14’ hatch. The crew faced a tight setup area for

the crane and limited staging area.


PROJECT PROFILESR

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The project had typical challenges, including a small set up

area, low ground bearing requirements, compressed critical

path timeline and congested work area. Barnhart’s team of heavy

industrial experts designed and engineered a single equalizing

rigging package that fit both heads, decreasing rigging costs

and lowering the exposure of having to change between rigging

packages for each lift.

Before the removal of one of the heads, an issue was

found with the lugs. Since the lead time for replacement

lugs was up to six days, Barnhart was asked to design a solution.

Between its robust engineering group and field experts, eight lifting

links were designed, engineered, fabricated and proof tested in

under 48 hours. This allowed the lifts to be completed within the

original schedule, much to the delight of the customer.

Barnhart was asked to partner with a refinery to provide lift planning, engineering and heavy lift services for the removal and

replacement of the plant’s Reactor and Regen heads in their Fluid Catalytic Cracker Unit. This was the first time the facility had

attempted the replacement of both heads within the same event, which complicated the work timeline and lift sequencing.


BARNHART WAS CONTRACTED TO LOAD TEST TWO TURBINE CRANES, INCLUDING PROVIDING A LARGE COUNTERWEIGHT STACK FOR A 300,000-POUND TEST.

Barnhart rigged the full stack for the main hoist first. Once

this portion of the project was completed, counterweight

was removed in order to test the auxiliary hoists.

Once the auxiliary hoists were tested, the full stack was

set back on the railcar and moved out of the protected

area where the equipment was demobilized. It was a challenge

to develop rigging and transport plans to move and lift this large

amount of counterweight, but the project was successfully

completed to the satisfaction of the customer.

The frame was set at a pre-determined location and

then the counterweights were stacked according to an

engineered drawing. Testing was to be done for the main hoists to

300,000 lbs. and the auxiliary hoists to 50,000 lbs.

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Barnhart was contracted to load test two turbine cranes at

a nuclear facility in Illinois, which included providing a large

counterweight stack for a 300,000-pound test. The counterweights

were trucked to the site. Barnhart then assembled the rigging, set

the lifting frame on the rail car and stacked the counterweights

outside the plant’s protected area. The frame and counterweights

were transported into the turbine building by railcar.


PROJECT PROFILESP

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: TRAN

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SPORT | M

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The road to the new substation was steep, winding and narrow. The crew had to navigate tight quarters while keeping the

trailer on the road. The transformers were then offloaded and set via crane at the site. All four transformers were delivered

safely and successfully.

Barnhart was hired to transport four transformers, which

arrived by rail, to a substation in Ann Arbor, Michigan. A

suitable rail spur had to be located, which was at a closed plant in

Milan, Michigan. The transformers were transloaded from rail cars

using a 500-ton Demag crane to a THP Goldhofer trailer.

The transformers were transported in pairs from the rail

spur approximately 20 miles to substation locations in Ann

Arbor. The trailer configuration was a four-line drop deck six-line THP,

designed to keep the ride height of the cargo low.

Since the city of Ann Arbor did not allow oversized transportation on home game weekends during University of Michigan football,

Barnhart had to adjust their schedule accordingly. They coordinated delivery with the rail service to transport on a Sunday in a convoy.


Once the reactor was sealed in the container, Barnhart

returned with the 350-ton crane and an additional 210-

ton crane to lift, tail and set the container on an EastTrac trailer

for transport.

The reactor was 20’ long x 10’ wide x 11’ tall and weighed

210,000 pounds. With it being an oversized load, it required

a dual-lane transporter to manage the weight. Even though the

cargo was a low-level nuclear load, it was placarded and required

HAZMAT-approved drivers.

The load was transported over 2,200 miles through nine states, each requiring DOT permitting. A special audit was required for the

transport team to gain entrance into the federal waste disposal site in Nevada.

A reactor had to be removed from a deactivated federal site in Arkansas. Barnhart was called in to not only remove the reactor,

but also to transport it to a disposal site in Nevada. The team used a 350-ton crane to lift it from the pit and set it into a shipping

cask container in the vertical position.

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With the original scope of the project complete, Barnhart

was then asked to provide over-the-road (OTR) trucking

services. The team used pull-up gantries to raise the vessel to the

proper height for loading.

The vessel was loaded onto a 13-axle OTR truck and trailer

for travel to a nearby scrap yard where the vessel was

offloaded with pull-up gantries. The project was executed safely

despite challenges, which included changing scope and schedule

delays due to extreme cold.

Once the vessel was in the yard, it was loaded to Barnhart’s

6-line PSTe and hauled to an onsite staging area where it

was placed on stands.

A 160,000-pound accelerator vessel was sitting in a storage

building at a national laboratory. Barnhart had moved the

vessel to the inside wall of the building two years earlier. Now it

had to be removed to make room for new equipment. The first step

in the process involved jacking and sliding the vessel out of a tight

wall opening that offered only five inches of clearance on each side.

THE PROJECT WAS EXECUTED SAFELY DESPITE CHALLENGES, WHICH INCLUDED CHANGING SCOPE AND SCHEDULE DELAYS DUE TO EXTREME COLD.


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The old ball mill was transported to an onsite laydown yard

where it was unloaded using 500-ton gantries. Barnhart

then loaded the new ball mill using gantries and reinstalled using

the reverse process. It was a tough job with a tight technical

solution that left zero room for error.

Barnhart was able to devise a solution that allowed the

ball mill to be replaced without removing any of the steel

structure or utilities, which saved the customer time and money.

The project was performed during an outage schedule so work

was performed 24/7 while abiding by MSHA safety rules. With

precise engineering and planning, Barnhart was successfully able

to remove and replace the ball mill in two shifts, allowing the

customer to minimize their outage schedule.

Once the mill was lowered, a Goldhofer hydraulic platform

trailer carefully drove the ball mill out of the structure. There

were tight clearances on all sides.

Barnhart was hired to remove and replace a 467,000-pound

ball mill measuring 45’ long by 14’ in diameter in a cement

manufacturing plant during an outage. The customer needed a

solution that avoided removing any of the structural steel and also

kept all utilities in place. This required Barnhart to lift the ball mill,

crab sideways and rotate 45 degrees. Then the team used a two-

step lowering process with pull-up gantries to lower the piece.


PROJECT PROFILESP

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: STATOR LIFT | W

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Using the gantries and 20’ long slide beams, the stator was lifted three feet in the air and held there for three days while a third party

contractor replaced the soul plates. While the job was planned for multiple days due to tight constraints and potential interference, the

team was able to complete it a day ahead of schedule.

The stator was in an enclosed building with many space

constraints that limited where Barnhart could put the

equipment and get the multipurpose girders into the building far

enough to be lifted by the overhead crane. There were mere inches

of clearance in several spots around the gantry legs, which were

within inches of obstructions on three of the four corners. This

made it difficult to get equipment and personnel into the same area

for leveling.

At a power plant in Washington, Barnhart was brought in

to engineer a lift of a 170,000-pound stator off its concrete

foundation to allow the soul plates to be replaced. They had less

than a month to create a workable plan and gather equipment to

execute. Their engineering team came up with a layout plan using

gantries and multipurpose girders.


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Barnhart constructed a custom lifting and transport frame using a combination of Barnhart 16” and 8” deep slide beams. The

frame was supported in four locations using 8” x 4” tube steel. The tubes were affixed to the bottoms of the beams using

sandwich plating and all-thread. The frame was shackled to two 120k Rigger Lift masts with rigging lugs and rigging chain.

The two Rigger Lifts worked in tandem to transport the cargo through the plant.

The overall transport height of the frame was 14’ 6 ½”, which meant there was a

mere six inches of clearance under the lowest rack.

The move took roughly half a

shift, and the work was performed

while the plant was operational. Once the

last obstacle was navigated, the shelter

was offloaded with the Rigger Lifts to

elevated piers. The project was executed

successfully and on time.

A refinery in Ohio had a problem. A 50-foot-long electrical shelter building had to be transported a half mile from one side of the

plant to the other. However, numerous overhead obstacles prevented a traditional transport. Barnhart had worked with the refinery’s

sister facility, so they were called in and challenged with determining a safe way to transport the 14‘ x 12.5’ x 50’ shelter building under

eight pipe racks, with the lowest overhead clearance at 15’ 2“ from grade.


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Barnhart was contacted to provide engineering, rigging

and transport services for an emergency job to remove a

damaged Combustion Turbine Generator (CTG) and install a new

Combustion Turbine (CT) and CTG at a power plant in Texas.

Barnhart mobilized as soon as possible to remove the old, damaged

CTG using our gantry system, which was assembled to require only

one set up for the entire project.

Upon removal of the old CTG, Barnhart transported it on

site using a 10-line PSTe Goldhofer and staged it on stands

and beams in the plant’s laydown yard. Movements on paved

sections using the PSTe Goldhofer were primarily done in the

cooler early morning hours using composite matting to prevent

damage to the pavement from the heavy transporter.

An additional gantry was set up at

the adjacent railyard to receive the

new equipment, the 525,000-pound CT and

565,000-pound CTG. A large section of

the haul road from the rail to the site was

not paved, which again required composite

matting to be placed its entire length to

prevent sinking or undermining of the road.

On site, the new generator

and transporter faced tight and

challenging maneuvering constraints.

Using the previously installed

gantry, Barnhart lifted both the

CT and CTG from the PSTe Goldhofer and

as shown here, traveled the CT to the

foundation where it was rough set. The

pieces were moved and relocated safely

and efficiently within schedule.


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Barnhart was hired to receive and install a boiler at a distillery

in Kentucky. Barnhart provided crews and two cranes to

receive the 104,000-pound boiler, which was offloaded via a two

crane pick and rotated to its proper position where it could be set

to a Goldhofer self-propelled modular trailer.

The trailer hauled the 16’ x 12’-8” x 37’-10” boiler one mile

through the plant site and through overhead piping and

other obstructions.

There were extremely tight

clearances in rotational areas of

less than 2” in some places and overhead

electrical lines in close proximity.

Access to the boiler’s final

destination was through a window

opening. A gantry system was set up both

inside and outside the building. Outside, the

boiler was rotated using the self-propelled

trailer and set in line with the window. It

was then lifted and set to staging beams.

The boiler was then transported

through the window using

multipurpose girders and a slide system

on top of the girders, with clearances of

less than one inch. The gantry system

raised, slid and side shifted the boiler and

then lowered it into position. The job was

completed ahead of schedule.


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MEXICO

In the yard, the 69’ long rotor was suspended from

gantries and slings before being transloaded to a dual

lane transporter. Including the two accompanying semi trucks, the

transport system would weigh 700,000 pounds and take up two

traffic lanes.

The convoy traveled 350 miles to Clovis at approximately 25

miles an hour. While some of the journey took place on the

interstate, about 75% was on two-lane state roads. New Mexico

state troopers who accompanied the dual lane transporter set up

rolling road blocks, essentially clearing the oncoming lane so that it

could pass through. Photo credit: The Albuquerque Journal.

At the rail station in Clovis, the rotor was lifted off the

transporter and loaded onto a rail car for transport to

Virginia for repairs. Once the repair is completed, the rotor will be

transported back to Clovis, and Barnhart will perform the reverse

process to get the rotor reinstalled.

At a national laboratory in New Mexico, a 460,000-pound

rotor needed to be removed and transported to a rail station

for eventual repair. One of the challenges was finding a suitable rail

station due to a variety of permitting issues. On the sixth try, a rail

station 350 miles away in Clovis, New Mexico, was found. Barnhart

brought in a 400-ton hydraulic gantry system to remove the rotor

from the stator housing and placed it onto a Goldhofer PSTe 10-Line

transport for removal from the building.


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Formally Burkhalter Rigging, a longtime provider of rigging

and crane rental services, the branch also offers a wide

variety of transportation services and benefits from

Barnhart’s arsenal of specialized alternative rigging tools and

custom engineering.

The Columbus branch provides unique solutions to

challenging projects—from low headroom rigging solutions

to heavy transport or challenging component removal and

replacement projects.

“As Barnhart, we will continue the tradition of innovative

rigging, and now we have access to a nationwide network of

cranes and other equipment,” says Branch Manager Brooke

Burkhalter. “So if we don’t have what the job needs here,

we can easily get it.”

Whether your project takes place in a steel mill, a refinery or

in a nuclear plant, the Barnhart Columbus branch is ready to

serve. From its central location on Highway 45, the branch

has easy access to many locations plus the machines and

expertise to get the job done safely, efficiently and on budget.

COLUMBUS, MSBARNHART ’S COLUMBUS , M ISS ISS IPP I BRANCH I S A FULL-SERV ICE FAC I L I TY, SERV ING CUSTOMERS IN

NORTHEAST M ISS ISS IPP I AND SOUTH CENTRAL ALABAMA, INCLUD ING THE COMMUNIT I ES OF NORTHPORT,

STARKV ILLE , WEST PO INT, COR INTH , OXFORD, TUSCALOOSA , COLUMBUS , PH I LADELPH IA , GREENV I LLE

AND GREENWOOD.


BRANCH PROFILE


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EQUIPMENT PROFILE

The system was fully designed, fabricated and tested by

Barnhart in-house. The goal was to create a single load line

system that was a lighter weight than the traditional MoCCs

and more geared toward smaller components. Jobs such

as removal and replacement of valves, small gearboxes,

electrical cabinets, backup generators and anything weighing

less than 24,000 lbs. can be performed more easily with the

Mini MoCCs.

The maximum system deadweight is 21,600 lbs. (full

counterweight configuration) with many lifts capable of

being performed with a system deadweight of less than

18,000 lbs. This expands the range of acceptable cranes

Barnhart can use to support the mini MoCCs and facilitate

the lift. The maximum overall length of the beam is 40’.

The Mini MoCCs has many benefits. It doesn’t require an

external power supply. It ships as a legal truckload and

requires no assembly equipment for setup. Lightweight by

comparison, the single load system requires no additional

training for a crane operator to work with the equipment.

Operation of the system is performed separately from the

operation of the crane and always by a qualified Barnhart

team member.

MINI MOCCSBARNHART ’S M IN I MOVABLE COUNTERWE IGHT CANT I LEVER SYSTEM (MOCCS ) I S A SMALLER VERS ION OF

OUR POPULAR CANT I LEVER SYSTEM WHICH CAN WORK WITH MOB ILE CRANES , OVERHEAD CRANES , AND

TOWER CRANES .

• DECATUR, AL | FULL SERVICE

• GADSDEN, AL | FULL SERVICE

• MOBILE, AL | FULL SERVICE

• BLYTHEVILLE, AR | FULL SERVICE

• LITTLE ROCK, AR | FULL SERVICE

• PHOENIX, AZ | RIGGING & TRANSPORT

• LONG BEACH, CA | RIGGING & TRANSPORT

• MIDDLETOWN, CT | FULL SERVICE

• AMES, IA | FULL SERVICE

• CEDAR RAPIDS, IA | FULL SERVICE

• DES MOINES, IA | FULL SERVICE

• MASON CITY, IA | FULL SERVICE

• CHICAGO, IL | RIGGING & TRANSPORT,

• EAST MOLINE, IL | FULL SERVICE

• LADD, IL | FULL SERVICE

• FOWLER, IN | FULL SERVICE

• CALVERT CITY, KY | FULL SERVICE

• OWENSBORO, KY | RIGGING & TRANSPORT

• BATON ROUGE, LA | FULL SERVICE

• SHREVEPORT, LA | FULL SERVICE

• WEST MONROE, LA | FULL SERVICE

• MONROE, MI | RIGGING & TRANSPORT

• JACKSON, MS | FULL SERVICE

• LINCOLN, NE | FULL SERVICE

• OMAHA, NE | FULL SERVICE

• SOUTH SIOUX CITY, NE | FULL SERVICE

• OKLAHOMA CITY, OK | FULL SERVICE

• CANTON, OH | FULL SERVICE

• PORTLAND, OR | FULL SERVICE

• PHILADELPHIA, PA | RIGGING & TRANSPORT

• CHARLESTON, SC | RIGGING & TRANSPORT

• SIOUX FALLS, SD | FULL SERVICE

• CHATTANOOGA, TN | FULL SERVICE

• KINGSPORT, TN | FULL SERVICE

• KNOXVILLE, TN | FULL SERVICE

• MEMPHIS, TN | FULL SERVICE, SERVICE

CENTER, HEAVY LIFT TERMINAL

• HOUSTON, TX | RIGGING & TRANSPORT

• HAMPTON, VA | FULL SERVICE

• KENT, WA | FULL SERVICE

• MT. VERNON, WA | FULL SERVICE

• RICHLAND, WA | RIGGING & TRANSPORT

• SPOKANE VALLEY, WA | FULL SERVICE

ALTERNATIVE HEAVY LIFT• MODULAR LIFTING TOWER

• PULL-UP GANTRY

• HYDRAULIC SLIDE SYSTEM

• JACKS & RAMS

• 4-POINT GANTRY SYSTEM

• STRAND JACKS

• MODULAR HOISTS

TRANSPORTATION SYSTEMS• DUAL LANE TRANSPORTERS

• GOLDHOFER PSTE

• HYDRAULIC DOLLY SYSTEMS

• BARGING

• RAMPS AND TEMPORARY BRIDGES

MARINE HEAVY LIFT• DERRICK CRANE – MISSISSIPPI RIVER

• BARGE CRANE – GULF COAST

• BARGE CRANE – GREAT LAKES

• HEAVY LIFT TERMINAL – GREAT LAKES

• HEAVY LIFT CRANE – HOUSTON

TELESCOPIC BOOM CRANES• FROM 7 TONS TO 650 TONS

LATTICE BOOM CRANES• CRAWLERS FROM 100 TO 1800 TONS

• TRUCK CRANES FROM 115 TO 800 TONS

• RINGER CRANES FROM 360 TO 1,800 TONS

OPERATED CRANE SERVICE• OVER 450 CRANES

• LATTICE BOOM TO 1,760 TONS

• TELESCOPIC BOOM TO 600 TONS

• FULL TURNAROUND SERVICES

• NATIONWIDE NETWORK OF CRANE

BRANCHES

2163 Airways Blvd.Memphis, TN 38114

[email protected]

NATIONWIDE OFFICE LOCATIONS & FACILITIES

BARNHART EQUIPMENT

PRESORT STDU.S. POSTAGE

PAIDTAMPA, FL

PERMIT NO. 2397

Documents

LIFTING LETTER - Barnhart Crane & Rigging · The project was performed during an outage schedule so work was performed 24/7 while abiding by MSHA safety rules. With precise engineering