MS Rigging Turbine - Santo Domingo - Rev04

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Appendix 4 to TCC ZEN000-DD04-0630-003, Rev.

2: On-Carriage at Site (“setdown onto foundation”)

Contractor:

Project: Customer: SIEMENS PG PKZ:


(Project Code)

Method Statement No.: Rev.: Date: Page: 1 of 6

1) 1) 1)
Prepared by Service Provider : Reviewed by Service Provider : Released by Service Provider :
Name / Date Signature Name / Date Signature Name / Date Signature
César Vinces Juan Luis Aldo Macassi
22/01/13 Sánchez 22/01/13
22/01/13
2)
Released by Contractor: Released by Independent Expert :
Name / Date Signature Name / Date Signature Name / Date Signature

Released by SIEMENS PG: Released by SIEMENS PG: 2nd Release by SIEMENS PG


SSM:
Name / Date Signature Name / Date Signature Name / Date Signature

Trade: Component: Turbine


Scope of work: On-carriage at construction site including setdown on foundations

Brief description of work to be performed:

Unloading of a turbine from the hydraulic trailer with the gantry system and placement onto foundations for
Santo Domingo Project

Sequence of operations:

1 Assembly of gantry tracks and partial compo- 6 Assembly of tracks (partial component)
nents
2 Parking of trailer with turbine 7 Roll in the gantry with turbine onto foundations
3 Finish the assembly of legs & header beam 8 Unload turbine onto foundations
4 Lifting of turbine 9
5 Trailer roll off trailer 10

Management structure:

- Project administrator / transportation Juan Luis Sánchez


coordinator
- Site supervisor César Vinces
- H&S officer César Silva
- Out-of-hours contact name Aldo Macassi
- Out-of-hours phone no. 999666626
- Who checks the work? Juan Luis Sánchez
1)
Service Provider and Contractor may be same company.
Appendix 4 to TCC ZEN000-DD04-0630-003, Rev.2: On-Carriage at Site (“setdown onto foundation”)

Contractor:

Project: Customer: SIEMENS PG PKZ:


(Project Code)

Method Statement No.: Rev.: Date: Page: 2 of 6

2)
Contracting at Siemens ESM4 discretion

Safety and operational details: (mark with a cross / add as necessary)


Crane Barge Skidding system
Floating crane Ocean-going vessel Gantry System
Heavy-load vehicle, road Ship lifting gear
Heavy-load vehicle, rail Lashings
Ro-Ro operations Mobile lifting equipment

Must consideration be given to third-party installations? (power / gas / water / communications equipment)
If yes, state necessary precautions: Foundations and alternative equipment should be covered by Siemens
to allow trailer access and tracks placement. Two concrete sidewalks will be made by Siemens to allow tracks
placement.

Transshipment at or within jobsite onto internal transport vehicles N/A


Appendix 4 to TCC ZEN000-DD04-0630-003, Rev.2: On-Carriage at Site (“setdown onto foundation”)

Contractor:

Project: Customer: SIEMENS PG PKZ:


(Project Code)

Method Statement No.: Rev.: Date: Page: 3 of 6

H/L-trailer for Ro-RO Operation Description of Manufacturer:


Manufacturer Drawings:
N/A Manufacturer Load Table:
Drawings for the respective No. of axles:
transport with indication of:
Distance between axles:
Main dimensions:
N/A
Radii:
Center of gravity:
Possible load distribution devices:
Prime mover:
SPMT:
Lashings Position of lashings (drawing):
N/A Load balance calculation acc. to VDI 2700, DIN/Euro-standards or similar:
Load tables with indications on: Vehicle weight:
Load weight:
N/A Total weight:
Load per axle:
Load per tire (footprint load):
Shadow load

Indication on all necessary load Drawings:


bearing parts, like load distribu-
Statical calculations:
tion devices, etc:
Certificates:
N/A
Appendix 4 to TCC ZEN000-DD04-0630-003, Rev.2: On-Carriage at Site (“setdown onto foundation”)

Contractor:

Project: Customer: SIEMENS PG PKZ:


(Project Code)

Method Statement No.: Rev.: Date: Page: 4 of 6

Mobile lifting equipment Manufacturer's descriptions, drawings and operating instructions.


Loads imposed by lifting equipment in outdoor areas as well as in or on
Please see attached documents building structures.
& drawings
Provisions for load distribution in outdoor areas as well as in or on building
structures, if necessary.
Description of setup and removal of mobile lifting equipment and auxiliaries
such as: truck crane, building crane, rope hoists, etc.
Detailed Level 3 time schedule for entire operation (delivery of heavy lifts
and mobile lifting equipment, setup of lifting equipment, transportation off
site, etc.).
Static analysis of mobile lifting equipment with test certificate issued by in-
dependent third party (TÜV, Lloyds, etc.).
Commercially available conveyor systems shall be certified by means of
manufacturers' certificates and/or in-service inspections.
For special designs of conveyor systems the Service Provider shall verify
their safety by means of static analyses.
Information on allowable assembly tolerances (parallelism of tracks, edge
offset, differences in elevation, angular misalignment, etc.). Compliance
with tolerances shall be recorded during assembly of mobile lifting equip-
ment.
Information on allowable tolerances under load (sagging/deflection, angular
misalignment, etc.). Compliance with allowable tolerances shall be continu-
ously monitored and recorded during entire foundation setdown operation
(lifting, traversing, lowering/setting down).
Information on deployed monitoring equipment (camera, theodolite, spirit
level, etc.) with which compliance with allowable tolerances is checked and
registered during foundation setdown operation.
Certificates for lifting equipment (lifting system, ropes, shackles, connecting
pieces, etc.).
Organization chart stating names of persons responsible for individual ac-
tivities.
Qualification records/certificates for all personnel deployed for the various
tasks (incl. managers and H&S officers/representatives).
Appendix 4 to TCC ZEN000-DD04-0630-003, Rev.2: On-Carriage at Site (“setdown onto foundation”)

Contractor:

Project: Customer: SIEMENS PG PKZ:


(Project Code)

Method Statement No.: Rev.: Date: Page: 5 of 6

How will the following risks/hazards be minimized?


- Falling / sinking / burial N/A
- Hazardous substances N/A
- High-voltage power lines N/A
- Drowning N/A
- Confined spaces / tanks N/A
- Falling objects EPP
- Use of machinery STIGLICH ISO 9001-2008 Guidelines & training
- Loads weighing more than STIGLICH ISO 9001-2008 Guidelines & training
10 tons each
- Suspended Loads STIGLICH ISO 9001-2008 Guidelines & training
- Others N/A
What temporary services are required? Provision
- Power Yes, 3 phase 220/440 V By Siemens at site
- Lighting Yes after 5 p.m. by Siemens at site
- Water N/A by
- Other by
Are actions related to traffic control equipment required? NO
If yes, give details:
Is a more detailed Method Statement required? Yes / No If yes, specify

List of applicable documents


Title: Document No.: Rev.:

 Drawing - Complete rigging sequence Appendix 1

 Drawing – Rigging sequence - Step 1 Appendix 2

 Drawing – Rigging sequence - Step 2 Appendix 3

 Drawing – Rigging sequence - Step 3 Appendix 4

 Drawing – Rigging sequence - Step 4 Appendix 5

 Track setting and supports Appendix 6

 Drawing – Lifting wires and shackles Appendix 7

 Load calculations for I-beams Appendix 8


Appendix 4 to TCC ZEN000-DD04-0630-003, Rev.2: On-Carriage at Site (“setdown onto foundation”)

Contractor:

Project: Customer: SIEMENS PG PKZ:


(Project Code)

Method Statement No.: Rev.: Date: Page: 6 of 6

 Drawing – Header beams loads Appendix 9

 Load Calculations for Lifting rings Appendix 10

 Pre lift Planning checklist Appendix 11

 Gantry loading chart 4 point Appendix 12

 Track loading capacity Appendix 13

 Certificate of Gantry Appendix 14

 Shackles loading chart Appendix 15

 Lifting wires loading chart (first set) Appendix 16

 Lifting wires loading certificate Appendix 17

 Rigging Guidelines – D/d ratio and effect on Appendix 18


sling capacity

 Track set up procedure Appendix 19

 Rigging sequence Appendix 20

 Organization Chart Appendix 21

 Qualification Records Appendix 22


Elaborado:
CVF

APPENDIX 8
Revisado:
I Beam load calculations – Rigging of Turbine AMP

197 TM Aprobado:
RSJ

 I Beams 1 and 2 :

Material A50
We are considering a 10% overload regarding the static situation presented on the drawing
Appendix 9.

Fig. 1 Dimensions for the section of I beams 1 and 2

Fig. 2 Load Distribution on I beams 1 and 2


Elaborado:
CVF

APPENDIX 8
Revisado:
I Beam load calculations – Rigging of Turbine AMP

197 TM Aprobado:
RSJ

Fig. 3 Acceptable result for I beams 1 and 2

 I beam 3 :

Material A36
We are considering a 10% overload regarding the static situation presented on the drawing
Appendix 9.

Fig. 4 Dimensions for the section of I beam 3


Elaborado:
CVF

APPENDIX 8
Revisado:
I Beam load calculations – Rigging of Turbine AMP

197 TM Aprobado:
RSJ

Fig. 5 Load Distribution on I beam 3

Fig. 6 Acceptable result for I beam 3


Elaborado:
CVF

APPENDIX 8
Revisado:
I Beam load calculations – Rigging of Turbine AMP

197 TM Aprobado:
RSJ

 I beam 4:

Material A36
We are considering a 10% overload regarding the static situation presented on the drawing
Appendix 9.

Fig. 7 Dimensions for the section of I beam 4

Fig. 8 Load Distribution on I beam 4


Elaborado:
CVF

APPENDIX 8
Revisado:
I Beam load calculations – Rigging of Turbine AMP

197 TM Aprobado:
RSJ

Fig. 9 Acceptable result for I beam 4


Elaborado:
CVF
APPENDIX 10
Revisado:
Cálculo de los Anillos del Gantry – Maniobra de AMP

Montaje de la Turbina 197 TM Aprobado:


Fecha:
RSJ
25-02-13

Anillos rojos del gantry


Material: ASTM A36
Esfuerzo máximo a la fluencia: 36 ksi o 248.21 MPa

Dimensiones:

Fig. 1 Dimensiones de los anillos

Modelo de elementos finitos de los anillos:

Fuerza de 31 856 N aplicada en 18 nodos, lo que da un


total de 573 408 N o 58.45 TM. Esta es la fuerza máxima
aplicada a un anillo considerando un 15% de sobrecarga
sobre las vigas.

Fig. 2 Modelo de elementos finitos, fuerza máxima aplicada a un anillo 58.45 TM.
Elaborado:
CVF
APPENDIX 10
Revisado:
Cálculo de los Anillos del Gantry – Maniobra de AMP

Montaje de la Turbina 197 TM Aprobado:


Fecha:
RSJ
25-02-13

Restricciones consideradas en el modelo de elementos finitos en el anillo:

Fig. 3 Restricciones. Fijo en la parte en que se apoya con la viga y fuerza aplicada.

Esfuerzo máximo presentado en el anillo:

Fig. 4 Esfuerzo máximo en el anillo, 96.579 MPa


11
APPENDIX 10

Santo Domingo 48A


87844 A
S SIEMENS 4 pls. Lift Systems Inc
March2013
March 2013 4
CHILCA 3856 Kg each leg
Turbine
04

Turbine

197 ton
Manufactures drawing
SIEMENS

second
100 ton 127 kg second
none

75 ton 99 kg 5784 mm
4 points
21304 kg 150 MT

218304 kg 38.60 %

César Vinces Fox 22/01/13


APPENDIX11
APPENDIX 12
APPENDIX 12
APPENDIX 13
APPENDIX 14

CERTIFICATE OF GANTRY

Pendiente, en espera del documento emitido por la certificadora.

Pending, waiting for the document issued by the certifier.


14
APPENDIX 15
APPENDIX
APPENDIX 13
16
APPENDIX 17

Form No.
CS BEAVER S.A.C. CS1
Note: Certificate No.: CSB. –1023-2008
This Certificate is based on the standard Require by : STIGLICH
international form as recommend by the
TRANSPORTES SA
International Labour Office in accordance
with ILO Convention No 152., OSHA/ASME
and ANSI. AP-Register-No.: 09-2008

Orden de Compra: 2003017531

Certificate of test and thorough examination of Lifting Appliances

(1) (2) (3) (4) (5)


Description of lifting appliances (with Date of test Angle to the Test load Safe working
distinguishing numbers or marks, if any) Inspection horizontal or (tons) load (SWL)
which have been tested and thoroughly radius at which 5-1 Safety
examined. test load applied Factor

02Sets Sling TRI FLEX Wire Rope


1 1/2” 6X25 IWRC 5.30Mts. long. Eye to 11/09/2008 N/A N/A 55.00ton.
eye
Marks: AI-0211

Position of Lifting Appliance and special conditions for the use see Rigging Plans.

Approved by OSHA ASME and ANSI

These Rigging Plans and Inspections are attached to the Register Book (OSHA 1910.184 and ANSME B30.9).

Surveyor of CS Beaver S.A.C


Name and address of the firm or competent person
Av. Elmer Faucet 281-283 San Miguel Lima 32
who witnessed testing and carried out thorough
Mr. Walter Quispe Huaman
examination:

I certify that the Lifting Appliances shown in column (1) were thoroughly examined and no defects or permanent
deformations were found; and that the safe working loads are as show.

Date : Thursday 11 September 2008


Place: San Miguel-Lima-PERU

Signature:____________________________
Walter Quispe Huaman
Surveyor
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APPENDIX 18

home >> products >> wire rope lifting slings >> Rigging Guidelines >> D/d Ratio and the effect on sling capacity

D/d Ratio and the effect on sling capacity

Sling Removal Criteria


to Rigging Guidelines Main Page
The Flexibility of Slings

Rigging Guidelines

Unirope Tag System The D/d Ratio is the ratio of the


diameter around which the sling is
bent divided by the body diameter
Detailed Wire Rope of the sling.
Lifting Sling Data:

9-part Gator-Flex® Slings Example: A 1/2" diameter wire


rope is bent around a 10" diameter
9-part Gator-Laid® Slings
pipe; the D/d Ratio is 10" divided
3-part Tri-Flex® Slings by 1/2" = D/d Ratio of 20:1

Single Part Standard Slings This ratio has an effect on the rated
capacity of slings.
2-leg Bridle Slings

3-leg Bridle Slings

4-leg Bridle Slings When a wire rope is bent around any sheave or other object there is a loss
of strength due to this bending action. As the D/d ratio becomes smaller this
loss of strength becomes greater and the rope becomes less efficient. This
curve relates the efficiency of a rope diameter to different D/d ratios. This
Endless- or Grommet Slings
curve is based on static loads and applies to 6-strand class 6x19 and 6x37
wire rope.

Eye & Eye Slings

The LOOP of an eye & eye sling has nearly DOUBLE the strength of it's body. For this reason the D/d
ratio in the LOOP is just half as critical as opposed to when the sling is used in BASKET hitch.

In most cases the shackle or hook over which the sling is placed will have a sufficient D/d ratio. On
the other hand, do not place too LARGE an object into the sling eye as this will result in splitting
forces affecting the sling splice and sling safety. The object (a shackle, a crane hook, a steel bar,....)
you place into the sling eye must not be larger than 1/2 of the sling eye length.

When a sling is used in a BASKET- or CHOKER HITCH with D/d ratios smaller than listed in the
capacity tables, the rated capacities (or WLL's) must be decreased.

For example: The BASKET and CHOKER hitch capacities listed (in all Standards and Regulations) for
6-strand ropes are based on a minimum D/d ratio of 25:1

An object you place into a 1" diameter 6-strand wire rope sling using a basket- or choker hitch must
have a minimum diameter of 25". If the object is smaller than the listed 25:1 D/d ratio the capacity
(or WLL) must be decreased. Table A) illustrates the percentage of decrease to be expected.

Note: The minimum D/d ratio for GATOR-FLEX® and for TRI-FLEX® slings are just 5:1. If you need to
lift small objects and don't want your sling to kink or bend permanently use these types.

Eye length must If the shackle If the object lifted with a 6- If the shackle or It is better to use a
NOT be smaller than body has AT strand wire rope sling in a object has 2 times larger shackle or a Wide
twice the object LEAST the same basket hitch is at least 25 x the diameter of a 6- Body shackle type. If the
(e.g. a hook) diameter as the larger than the sling diameter strand wire rope shackle or object has at
diameter. sling (D/d 1:1) (D/d 25:1) the basket capacity sling (D/d 2:1) the least 5x the sling
the capacity need not to be adjusted. basket sling capacity diameter (D/d 5:1) the
need not to be must be reduced by basket sling capacity
adjusted 40% must still be reduced by
about 25%.

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Crosby® Wide Body Standard shackles have round Load Hooks must have sufficient thickness to ensure proper
shackles are available in stock bodies and come in sling D/d ratio, particularly when using slings in an inverted
capacities ranging from capacities ranging from 1/3 tons basket hitch; that is the sling BODY is placed into the hook
75 tons to 1000 tons. to 400 tons and the sling EYES are facing downward

Endless Slings

Endless (or Grommet) slings DO NOT HAVE A LOOP which has double the strength of the sling body.
Prior to EVERY lift YOU, the user, has to determine if the D/d ratio is equal or higher than the ones
listed in the capacity tables.

For endless 6-strand and Gator-Flex endless type wire rope slings the rated capacities have already
been adjusted to be used at a D/d Ratio of 5:1.

See the WLL Tables for details.

Use large enough If possible use Wide- Proper D/d ratio for the Small diameter shackles reduce the sling strength
hooks AND large Body shackles. They sling capacity. If the sling and, most likely, that small diameter shackle also
diameter shackles increase the D/d ratio is too short you may has insufficient capacity for that job.
to avoid crushing and you gain sling have to adjust the Shackle or not, objects to be lifted and all hook
and kinking of the strength. capacity because of the up points MUST at least ensure a D/d Ratio of
sling. sling angle. 5:1.

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APPENDIX
APPENDIX 15
19
Elaborado:
CVF FC-04-16
Appendix 20 Revisado: Revisión:
Rigging secuence with Gantry System AMP
Aprobado:
01
Fecha:
for Turbine RSJ 25-02-13

OPERATION DETAIL:
Date: February 2013

Client: SIEMENS

Operational Nº: OP 2008000

Load: Turbine

Weight: 197 ton.

WORKING PROCEDURE:

To execute the rigging of the turbine onto foundations the trailer platform will be parked parallel
and as close as possible to the turbine foundations. The trailer platform will transit over a dirt
filling and soil compact prepare for the rigging job.

Once the platform is parked the turbine will be lifted using the Gantry system, so that the trailer
will roll off. The missing truck portions will be installed on track A & B (for track A dirt filling
will need to be removed before placed of the missing track portion).

The turbine will travel towards its foundations lifted by the gantry system.

To perform the operation described above, the following work will need to be performed
previously:

TRACK ASSEMBY

 Both tracks will be assembled perpendicular to the turbine concrete foundations


as per the drawings attached to the method statement.
 Both tracks will be assembled parallel among them with a height difference of 300
mm. The height difference will be created by the dirt filled needed for the
platform roll on.
 On track A the assembly will leave the corresponding space for the missing track
portion, that later will have to be placed after lifting the turbine and removing the
dirt filling.
 On track B the assembly will leave the corresponding space for the missing track
portion, that later will have to be placed on concrete slab after lifting the turbine.
An additional portion of this track line will be supporting over timber wood, to
maintain the track level.
 Both tracks A and B will be leveled and parallel within the accepted tolerance.
 Gantry legs will be placed on top of the tracks A and B and they will roll to test
the truck support.
 Header beams and cross beams will be lifted and position over the Gantry legs.
The cross beams will have the corresponding lifting beams and cables for this
lifting. All header beams will be secure to the gantry legs.
 The beams will be lifted by the gantry legs in order to leave enough height to
allow the truck roll on with the turbine.
 Once the truck is in position the lifting wires will be hooked on the turbines 4
lifting points
 One assistant will be at each leg to control the lifting heights. They will be
communicated by radio with the control area.
 The I beams height will be adjusted so they will be leveled, horizontal and
squared.
 Cargo, will be lifted 50 mm on top of the platform and we will wait 5 minutes to
assure that the rigging and gantry legs are working correctly. The gantry tracks
and concrete slab will also be supervised.
 Once the turbine is lifted for the first time we will evaluate if the center of the
turbine is at the correct position in relation to the cross beams and gantry legs, if
this center line is not correct the turbine will be lowered to the trailer platform to
shift the lifting links so the turbine can achieve the correct center line. This
operation will be made as many times as needed, so the cargo load is well
distributed and will facilitate its arrival and placement on foundation.
 The gantry legs will increase their height by 100 mm each time. The height will
be controlled by measuring tapes on each towel. Everytime we finished to lift 100
mm. a height control check will be made by radio to level all four pistons, in order
to continue with the next lifting.
 The trailer platform will roll off
 The missing portions for track A and B will be placed and secure within the
acceptable leveling and parallel measurements.
 The turbine will start to travel by using hydraulic pistons to move them towards
the foundation at 1,200 mm each time. The alignment of the towel will be visual
and will be reported by radio from the assistant to the control area in order to
travel evenly; therefore reporting if the legs should adjusted forward or back.
 The distance between the gantry legs on the same track will be maintain due to
the spreader. Therefore allowing to move as one block.
 Approximately 2 or 3 m. before the arrival to its foundation the hydraulic pistons
will start to push the turbine towards its final position and aligned to the turbine
foundation access.
 The turbine will be lower and position onto foundations by decreasing the height
by 50 mm. each time.

Siemens will provide one crane for the gantry assembly, electrical panel with the proper power to
run the gantry system as well as will prepare the soil compact and access by clearing the
obstacles, leveling and compacting the working area.

Cesar Vinces Christian Figueroa Aldo Macassi

SUPERVISOR DE OP. ESPECIALES JEFE DE OPERACIONES GERENTE DE OPERACIONES


Elaborado:
CVF

APPENDIX 21 Revisado:
AMP
Organization Chart
Aprobado:
Fecha:
RSJ
25-02-13

Operation Manager
(Aldo Macassi)

Project Manager
(Juan Luis Sánchez / Mario
Vega)

Assembly Gantry Rigging Gantry Supervisor H&S Officer


Supervisor (César Vinces) (César Silva)
(Martín Alvarez)

H&S Supervisor
(Wilmer Heredia)
Elaborado:
CVF

APPENDIX 22 Revisado:
AMP
Qualification Records
Aprobado:
Fecha:
RSJ
25-02-13

Nombres y Apellidos Cargo Experiencia (años) Últimos Trabajos


Realizados
José Ayala Reyes Driver 10 UTC Overseas – San
Gabán (Trafo)
Bucyrus – Antamina
(Perforadora)
Gloria S.A. – Yura (Taza)
Xstrata – Tintaya
(Chancadora)
Xstrata – Tintaya (Trafos)
Enersur – Chilca (Trafo)
Posco – Chilca
(Estructuras)
Cristian Portilla Vásquez Driver 6 Min. Cerro Verde – Cerro
Verde (Rodillos)
Min. Cerro Verde – Cerro
Verde (Chasis 793)
AMPCO – Huaral
(Estatores)
P&H – Antamina (Grúa)
Ferreyros – Antamina
(CAT 854)
Xstrata – Antapaccay
(Molinos)
Ferreyros – Antamina
(Excavadora 385L)
Gloria S.A. – Yura (Taza)
Posco – Chilca
(Estructuras)
Lenin Farfán Rangel Operator Hydraulic Trailer 13 Seil – Chilca (Estructuras)
MIQ – Recepción
(Estatores)
Ausa – Chilca
(Estructuras)
SSK – Chilca (Trafo)
Enersur – Chilca (Trafo)
MIQ – Corcona (Shells)
Posco – Chilca
(Estructuras)
MIQ – Toromocho (Sala
Eléctrica)
MIQ – Toromocho (Fajas
Transportadoras)
Gerson Kikushima Sánchez Operator Hydraulic Trailer 12 Schenker – Pisco (Grúas)
Dimatic – Cerro Verde
(Sala Eléctrica)

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