AL.SK CRANES - ALE · PDF file7 DESIGN ALE first conceived the idea of a new land based...

AL.SK CRANES AL.SK190 - 4,300t CAPACITY AL.SK350 - 5,000t CAPACITY

WORLDWIDE HEAVY TRANSPORTATION AND LIFTING

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SMARTER

SAFER

STRONGER

At the heart of ALE’s business are our people: dedicated professionals who work with our clients to achieve the very best results. We employ imaginative people at all levels within the company, who focus on developing innovative solutions for the most complex projects. We challenge conventional thinking, aspire beyond accepted limitations, and don’t stop until we have the smartest, most effective solution to each and every challenge. Our Innovation Series is just one example of our insistence on pushing the boundaries to create solutions that work best for our clients.

ALE is a responsible business with a strong moral core, so the safety and well-being of the individuals we work with and the clients we work for is our single most important consideration. Minimising risk to our staff, our clients and members of the local community is a priority at the highest level of the company, and an ethos that permeates every aspect of our business.

We haven’t become one of the world’s foremost experts in heavy transportation and lifting by thinking small. By investing in the latest technologies and employing the best people in the business, we’ve grown over more than 30 years into a global leader with a presence across a breadth of sectors and markets. Our flexible approach suits any project, whatever its size or scale, and our clients know they can rely on us for commitment, innovation, delivery, service and an agile, proactive approach that gets results.

Together, we are...

Together, we are Smarter, Safer, Stronger

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CONTENTS OVERVIEW ALE has always been distinguished by its engineering capabilities. We’re recognised as a world leader in equipment and solution development, and from the opening of our Research and Development (R&D) facility, our innovative product design has dominated industry news and redefined the boundaries of heavylifting capability in a global market.

Our world-beating R&D facility works with teams around the world to find a solution for existing challenges and future issues before it’s needed. The fleet of innovations are designed with state of the art technologies using industry experts and includes the world’s largest capacity land based cranes, the AL.SK cranes.

5

Overview 5

Design 6

AL.SK190, AL.SK350 7

Overview of key features 8

DESIGN BENEFITS

Small Plot Area 10

Reduced on-site disruption 11

High Capacity & High Speed Lifting 12

Boom ‘Failsafe’ Topping System 14

Variable Ballast 15

Fixed Ring Configuration 15

Heavy Duty Jib Assembly 16

Simplified Logistics & Assembly 17

OPERATIONAL BENEFITS

Assembly 18

Even Ground Load Distribution 19

Ground Bearing Pressures 20

Ballast 21

Tailing Crane Location 22

Steering Winches 23

Faster on-site Relocation & Ground Settlement 25

Boom Erection 26

Slewing Operation 27

Operating Wind Speeds 28

Control Systems 29

Longer Reach for High Capacity Lifts 30

Nuclear 30

More Accurate Scheduling for Shipyard Applications 31

Safety Features, The Future & Engineering 32

Engineering & Feed Support 33

CASE STUDIES

EEP, Rio de Janeiro, Brazil 34

Valero Coker Interchange, Port Arthur, USA 35

RRE2, Ruwais, UAE 36

Thai Growth, Map Ta Phut, Thailand 37

MFC Project, Sadara, KSA 38

LPG4, Kuwait City, Kuwait 39

Sectors 40

Services 41

Equipment 42

Innovation Series 43


7

DESIGN

ALE first conceived the idea of a new land based heavylift crane in 2006. Our clients were looking to lift heavier items at a larger outreach while improving safety, lowering costs and reducing construction schedules.

With over 30 years in the business, ALE has forged close relationships with EPC contractors, fabricators and shipyards.

Following close consultation with a number of these leading companies, we defined our objectives for the project:

In addition to these high level objectives, the R&D teams designs focused on innovations to ensure that the AL.SK series was not simply a new crane, but a new type of crane altogether. By developing a solution that enables the AL.SK series to rotate around its ballast, the engineers were able to provide higher capacity and improved outreach. Unique honeycomb mats distribute load laterally and longitudinally with flexible connections rather than a fixed ring and allows the AL.SK to operate without the full ring. The design compensates for settlement. The crane is hydraulically self levelling to maintain verticality of the boom. The use of both strand jacks and winches create a combination of lifting options up to 5,000t capacity. ALE’s R&D team were also keen to ensure that the AL.SK series would de-rig for easy transportation in ISO 20ft and 40ft shipping containers and, of course, it was designed to the latest, most stringent global safety standards.

After a rigorous programme of testing, the AL.SK190 was launched in 2008 as the world’s largest capacity land based crane. Its enormous success and popularity led to a second being built and launched in 2011.

A new design of crane with the highest capacity in the market

The crane should be capable of being configured in different sizes

Speed and efficiency of smaller lifts should be maintained

Safety, accuracy and performance should be enhanced

AL.SK190

The AL.SK190 – named to indicate the measurement of the load moment based around the point of rotation, the industry standard for measuring the lifting radius of cranes – has a lifting capacity of 4,300t, a maximum boom height of almost 200m and a load moment of 196,000tm. It has two big advantages: it can perform lifts previously unachievable, and it can do this whilst occupying a footprint of just 35m x 55m.

The AL.SK190 was given the Innovation and Development award for end users at the 2010 ESTA Awards of Excellence.

AL.SK350

Due to the global demand for AL.SK cranes and for even greater capacity, the AL.SK350, launched in 2013 has now taken its place as the world’s largest capacity land based crane by some distance. With a lifting capacity of 5,000t and a load moment of 354,000tm, this crane enables the development of new and groundbreaking construction methodologies. It can save our clients time and money on the construction site by reducing schedule, risk and cost.

7Together, we are Smarter, Safer, Stronger

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OVERVIEW OF KEY FEATURES

• World’s largest capacity land based crane

• 5,000t capacity strand lift system

• 4,000t capacity winch system

• 600t capacity quick winch system

• Variable ring diameter

• Variable ballast radius

• Full ring available but not usually required

• Even ground load distribution and known imposed loads

• Capable of accommodating ground settlement

• High operating wind speed

• On-site relocation within five days

• Containerised for low cost shipping

• Local ballast used for low cost mobilisation

• Automated boom section assembly for safe working

Small plot area required to reduce on-site disruption}


SMALL PLOT AREAThe AL.SK’s central ballast design eliminates the need to install a full ring or crane track. It only needs the section required for the project – as little as 45 degrees – creating valuable on-site access routes for plant personnel and vehicles, and reducing occupancy of the lifting area by up to 45%.

DESIGN BENEFITS

REDUCED ON-SITE DISRUPTION

The large lifting radius allows the crane to be fully rigged and operated off-plot, with fewer lifting positions and less ground preparation. Foundation work can continue while critical pieces are installed, minimising disruption, reducing schedule and lowering cost.

Due to their enhanced design, the AL.SK series cranes are capable of operating at higher wind speeds than conventional crawler or ring cranes to reduce site down time.

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DESIGN BENEFITS


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HIGH CAPACITY &HIGH SPEED LIFTINGThe unique combination of winches up to 4,000t lifting capacity or strand jacks up to 5,000t lifting capacity (including the option for a 600t quick winch for smaller lifts) allows both small and ultra-heavy items to be lifted efficiently. Dependant on the reeving required, lifting speeds are up to 150m per hour.

DESIGN BENEFITS


BOOM ‘FAILSAFE’ TOPPING SYSTEMAs an additional safety system, the Boom Topping System comprises of a hydraulically operated chain clamping system that is mechanically locked during operation.

VARIABLE BALLAST RADIUS

With the ballast located centrally to the cranes’ rotation, the ballast radius can be adjusted to suit both lift and site conditions. This can increase lift capacity by 100% or reduce the cranes’ footprint by 75%. It also increases significantly the outreach over fixed ring cranes.

DESIGN BENEFITS

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FIXED RING CONFIGURATION

The AL.SK cranes are also capable of being configured with the ballast located on the ring, as a traditional ring crane. This configuration can be used when the superior lifting capability of the AL.SK cranes are not required.


HEAVY DUTY JIB ASSEMBLYThe AL.SK cranes can also be fitted with a heavy duty jib assembly for use with either the 4,000t winch or the 5,000t strand jack system. Lifting capacities of over 3,000t are possible with the jib, and jib lengths up to 80m are available for long reach lifts. Further details are available on request.

SIMPLIFIED LOGISTICS & ASSEMBLY

Containerised design and fast-assembly features minimises mobilisation and assembly time. ALE’s specialists can assemble the crane in only four weeks using standard plant and a 400t crawler crane.

DESIGN BENEFITS


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ASSEMBLYThe AL.SK fleet feature a unique hydraulic pin connection which reduces wear during service, saves time when assembling the crane and improves safety.


Hydraulic Pins

Hydraulic Pins


EVEN GROUND LOAD DISTRIBUTION

The unique honeycomb design of the load spreading mats enables uniform load distribution over the whole area of the mat.


GROUND BEARING PRESSURESProprietary load-spreading design and hydraulic systems ensures ground bearing pressures are kept to a minimum. For the AL.SK350, maximum ground bearing pressures beneath the 4,000t ballast system are 20.2t/m².

The average ground bearing pressure beneath the mast foot during medium range use is up to around 25t/m². The actual ground bearing pressures are dependent upon load case and configuration.


BALLAST

The AL.SK crane series utilises locally available ballast material, for example sand, gravel or other similar aggregate.

Specially reinforced 40’ open-topped shipping containers are loaded with ballast material and filled by standard mechanical shovel. The weight of each filled container is 100t, requiring around 4,000t of local ballast.

Together, we are Smarter, Safer, Stronger 21


TAILING CRANE LOCATION - SAVING SPACEThe high capacity of the AL.SK series cranes enables the lifting of large process columns with the column head located furthest from the crane. This allows the cranes to boom back during tailing to the vertical rather than in the conventional manner.

The tailing crane can be located at the boom foot of the AL.SK, rather than ‘on plot’ where additional ground preparation may be required.


STEERING WINCHES

Steering winches fitted to the backmast can be used to prevent the load rotating on the hook during lifting, avoiding the use of tag lines.

Steering winch


Hydraulic Cylinder


FASTER ON-SITE RELOCATION

Due to the AL.SK cranes’ unique design of the ballast being situated centrally and the cranes rotating around the ballast, it is also possible to relocate the cranes on-site in only a few days with the tracks laid parallel. This enables much faster on-site relocation compared to other options, such as SPMTs or dismantling the complete crane. It is also possible to skid the cranes sideways under load with the tracks laid parallel.

GROUND SETTLEMENT

A hydraulic cylinder positioned in each skid shoe can compensate by up to 400mm in height. Supporting the crane on hydraulic cylinders allows ALE engineers to calculate the exact ground-bearing pressure underneath the cranes at any position and any time. If surface settlement does occur, hydraulic cylinders elevate the mast foot to level the crane structure and reduce side loadings. As an additional safety feature, the pressure readings in the hydraulic cylinders are used to monitor the loads in the mast foot.

BOOM ERECTIONDuring assembly, the main boom is lifted and erected by the main topping system and back mast, thus avoiding the use of a large support crane for this operation.


SLEWING OPERATION

AL.SK cranes utilise a special design of gripper units capable of slewing up to 100m per hour under load, which means a 90 degree slew moment in under 30 minutes. They operate as a safety stop where ground settlement occurs or at high wind speeds and can lock the crane in position or slew the crane back to a safe condition.



Wind Speed Beaufort m/s Km/hr

Operational 7 14.4 52

Design 8 20 72

Survival 12 67 241

OPERATING WIND SPEEDSThe AL.SK series can operate with significantly lower downtime in a high wind environment to maintain schedule and reduce cost risk. The design of the AL.SK crane allows for operational wind speeds of 20m/s. A typical large crawler crane with a boom length of 80m is limited to an operational wind speed of circa 9m/s.


CONTROL SYSTEMS

The AL.SK control systems use the Siemens Programmable Logic Controllers (PLC) software. This allows for remote access for analysing, upgrading and problem solving to avoid downtime with real time access off-site.

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LONGER REACH FOR HIGH CAPACITY LIFTSWith a wider radius, the AL.SK cranes can lift up to 1,000t with a 300m rotation providing extended reach to areas inaccessible to crawler cranes. Clients can achieve significant reductions in equipment deployment, schedule and working areas.

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MORE ACCURATE SCHEDULING FOR SHIPYARD APPLICATIONS

A combination of increased capacity and lift radius means that the AL.SK cranes are an ideal alternative to floating cranes and crane barges for lifting modules directly onto vessel hulls. The work and schedule is less exposed to weather and independent of tidal conditions.

NUCLEAR

Using the AL.SK fleet we can create a bespoke lifting solution to fit within existing nuclear power stations - an ability that has won us recognition for our flexibility as well as multiple awards.

When required on-site at a new build power station, the AL.SK can be positioned at the centre of the facility where from one position the crane is able to install multiple pieces at various locations up to 5,000t in weight. All components such as reactors, steam generators, polar crane and dome can be lifted with one crane positioned in a single location.

With a small footprint and extended radius, the AL.SK cranes cause minimum impact while covering maximum ground and can be positioned inside the plant without any amends to infrastructure.

With capacities as high as this, clients are able to produce larger modules for less on-site construction.

31 Together, we are Smarter, Safer, Stronger

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SAFETY FEATURES, THE FUTURE & ENGINEERING

SAFETY FEATURESThe AL.SK cranes have been designed in accordance with the most stringent safety regulations. To gain third party approval, every stage was checked, witnessed and approved by globally recognised independent surveyors. Using these strict criteria ensures the very highest standards of design and fabrication.

BACK UP OPERATING SYSTEMSALE engineers have equipped the AL.SK cranes with primary, secondary and emergency backup systems in critical areas. The central control room provides crucial 3D monitoring systems during the project execution to oversee and ensure precision and accuracy.

THE FUTUREALE’s R&D facility continues to focus on improving current equipment and creating new solutions for the industry. Having a dedicated development facility gives our highly skilled engineers a platform from which to push the boundaries of design. With this expertise and a close working relationship with our clients, we have gained a comprehensive understanding of the market to develop equipment to meet both current and future demand. ALE is committed to proactively meeting the needs of our clients. Our foundations are not built as an equipment rental company, we actively develop solutions to challenges faced by clients and solve them through innovation.

The AL.SK crane series is also being extended. Although our current cranes are the largest available, our commitment to continuous improvement sees us already working on the 8,000t capacity AL.SK TWIN 700. In combination with our Mega Jack system we will break further industry records so the world’s leading offshore fabricators can rethink their construction methods and achieve their own innovation strategies. In this way, ALE is initiating and leading improvements across many industry sectors throughout the world.

SAFETY FEATURES, THE FUTURE & ENGINEERING

ENGINEERING & FEED SUPPORT

Our experience and pedigree in innovative engineering means we’re well equipped to support the process of project development in early engineering and FEED. ALE has contributed to many high profile projects at the forefront of technological innovation. In the long term we will continue to meet the industry’s ever-changing demands and improving safety standards. In the short term we are able to adapt as the scope of each project becomes more defined. We work closely with our clients from the very earliest stages, providing engineering advice to establish exactly what is required.

We believe that working through complex technical and logistical issues at the outset helps to eliminate expensive changes later.


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CASE STUDIES

ALE successfully demonstrated the key benefits of an extended lifting radius with a series of record-breaking lifts at an oil refinery in Port Arthur, Texas, USA. Using our AL.SK190 crane – the first use of this award-winning crane in North America – ALE completed a two stage project that involved lifting 1,338t at 54m outreach.

In the initial phase of the project, the AL.SK190 was used to exchange coker drums, removing six old drums and replacing with six new drums weighing up to 471t each. The crane first lifted a 1,400t derrick structure, which was positioned on top of the existing coker drums at a height of 100m, and set it on the ground. The coker drums were then exchanged, and the derrick structure replaced.

The derrick lift performed by the AL.SK190 was the first time a complete derrick assembly consisting of triple drill towers and cutting deck, had been removed and replaced in a single piece.

The lift required a complex tackle arrangement with a twelve point pick up only possible with the AL.SK190 crane. To successfully complete the project without the need to shut down the coker the AL.SK190 was rigged outside the boundaries of the coker pit. This also enabled the completion of the project with no permanent equipment in the refinery having to be dismantled, and the coke pit wall did not have to be removed.

In addition to the AL.SK190, an 850t tailing gantry and sixty axle lines of SPMT were utilised to complete the HCU installation. ALE also supplied all of the engineering calculations and related support.

CASE STUDYValero Coker Interchange, Port Arthur, USA


CASE STUDY

ALE installed an accommodation module, weighing 1,538t, and a service module, weighing 702t, on the Petrobras P-74 FPSO site in the Petrobras shipyard.

The challenge was to achieve this in the shortest possible timescale in order to maximise the cost efficiency of the project. The engineering solution was the use of the AL.SK190 crane. Its 118.5m main mast was positioned to reach and lift pieces from one single point without the need for the crane to be repositioned or the FPSO to be removed from the dock. The AL.SK190 crane performed three lifts over a ten day period to install the accommodation module, service module and the helideck.

EEP, Rio de Janeiro, Brazil

CASE STUDY

The AL.SK190 was required on-site at a project within the Ruwais area, UAE, at a refinery expansion project for a new build residual fluidised catalytic cracker unit (RFCC).

The project saw a total of 92 lifts, including seven in four separate locations with the AL.SK190. During these lifts the 1,600t capacity CC8800-1 was utilised as the tailing crane for the AL.SK190. The first of the seven pieces included an 1,100t reactor, a 1,200t main fractionator column, and a 1,900t regenerator.

In addition to serving as the tailing crane the CC8800-1 crane also completed sixteen lifts independently.

RRE2, Ruwais, UAE

ALE completed a series of lifts as part of the Thai Growth Project in Map Ta Phut, Thailand. With weights ranging from 73t up to 813t, twenty-five items were transported, lifted and installed in just twenty-two days.

The Thai Growth Project originally specified a large crawler crane from three positions, with the lifts taking place over a three-month period. However, the AL.SK190’s record-breaking capabilities reduced this to less than one month, achieving significant cost and schedule savings for the client.

Due to its high outreach capacity, the AL.SK190 was able to perform all required lifts from a single location, avoiding the expense and time associated with de-rigging, re-rigging and re-locating. Columns could be lifted over the new structure, enabling other structures and pipe racks to be installed ahead of schedule. The AL.SK190 also required minimal ground preparation for the 25t/m2 loading under the mast foot and 20t/m2 under the ballast.

The twenty-five items lifted as part of the project weighed a combined 4,230t. Key installations included:

• A 85m x 8ø column with a total lift weight of 850t and an installation radius of 114.4m

• A 75m x 8ø column with a total lift weight of around 700t, which had an installation radius of 70.6m

• 50m x 6ø column with a total lift weight of 250t and an installation radius of 110m.

CASE STUDYThai Growth, Map Ta Phut, Thailand

CASE STUDIES


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CASE STUDY

ALE completed 161 installations at a chemical plant in the Eastern province of Saudi Arabia.

To complete the installations which were to the Mixed Feeder Cracker (MFC), the team utilised the AL.SK190, the LR1800 - 800t capacity - as a tailing crane, and the CC2800-1 600t capacity crane. The AL.SK was used on the larger pieces up to 1,329t, where smaller loads ranging from 25t were installed by the CC2800-1.

MFC Project, Sadara, KSA

ALE was selected to complete the transportation and installation of 118 pieces including a De-ethaniser tower weighing 1,315t at a refinery in Kuwait.

Planning for the installation of the tower began almost a year prior to the operation. The transportation presented the biggest challenge with route surveys and route modifications required prior to the transportation by SPMTs.

On-site the lifts and installations by the AL.SK190 was completed using a fixed tailing frame for the two largest pieces and the CC2800-1 for the remaining pieces.

The success of the project was down to the AL.SK’s ability to independently install all pieces from one position.

LPG4, Kuwait City, Kuwait

CASE STUDIES


CASE STUDY

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SECTORS

CIVIL

OFFSHORE

POWER GENERATION

OIL, GAS & PETROCHEMICAL

RENEWABLES

MINERALS & METALS NUCLEAR

PORTS

SHIPYARDS

SERVICES

BALLASTING

LIFTING SYSTEMS LOAD-IN & LOAD-OUT MARINE ENGINEERING

CRANE LIFTING ENGINEERING

LOGISTICS

JACKING


SKIDDING TRANSPORTATION TURNKEY OPERATIONSOFFSHORE INSTALLATION WEIGHING

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EQUIPMENT

SKID SYSTEMS

JACKING SYSTEMS

LIFTING SYSTEMS

AUXILLARY, ANCILLARY & ACCESS EQUIPMENT

WEIGHING SYSTEMS

BALLAST SYSTEMS

BARGES

INNOVATION SERIES

CRANES

TRANSPORTATION

GIRDER FRAME

SPMT

SPECIALIST

MODULAR TRAILERS

SPT

CRAWLER MOBILE


ALL TERRAIN TRANSPORTERSMEGA JACK AL.SK CRANES

HYDRO DECK MEGA JACK 800

[email protected]

WORLDWIDE HEAVY TRANSPORTATION AND LIFTING

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AL.SK CRANES - ALE · PDF file7 DESIGN ALE first conceived the idea of a new land based...

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