PLANT: GAC GUINEA BAUXITE HANDLING PROJECT tkII– No.

West Africa
SPCPL: Barge Loader 001

ERECTION MANUAL

3 ERECTION SEQUENCE ...............................................................2

3.1 General Notes ............................................................................................ 2

3.2 Sub Structure ........................................................................................... 3
3.3 Slew Deck .................................................................................................. 3
3.4 Hoisting Cylinder ...................................................................................... 4
3.5 Boom with Shuttle ...................................................................................... 4
3.6 Hydraulic system ...................................................................................... 6
3.7 Electrical Equipment ................................................................................ 8
3.8 Counterweight ............................................................................................ 8
3.9 Ladders, Railings and Platforms ................................................................ 9
3.10 Lubrication.................................................................................................. 9
3.11 Completion of the BL .............................................................................. 10

ment shared for reference

 PLANT: GAC GUINEA BAUXITE HANDLING PROJECT tkII– No.
West Africa
SPCPL: Barge Loader 001

ERECTION MANUAL

3 ERECTION SEQUENCE
3.1 General Notes

The ship loader will be delivered in four main components:

- Boom
- Shuttle
- Sub Structure
- Slew Deck

These main components will be delivered by ship. For installation works, temporary erection
supports has to be set on the pier.

For the execution of the erection works of the ship loader please refer to:
G e n e r a l Arrangement of Barge Loader
Transport sketch
Erection support sketch
Operation & Maintenance Manual (O&M Manual)

Based on the above mentioned drawings and manuals, all detailed drawings required for the
execution of the subject are listed in the respective drawing list.

The erection and commissioning of the ship loader should take place in the presence of
ThyssenKrupp advisors.

Abbreviations: BL – Barge Loader

 Note: During erection, the measurements have to be checked in accordance to the

relevant drawings and corrected if necessary.

Prior start of erection all embedded parts are installed in accordance to GA drawings.
Furthermore all foundations have to be ready to bear the loads as mentioned in G A drawing.

 Note: Before lifting of the parts, the weights have to be checked with the actual
packing list and to be controlled with the crane capacities!

Attention: The weld back current cable has to be positioned close to the
weld joint! All welds have to be performed and checked in
accordance to their drawings, welding procedures and
specifications, and have to be approved by the client! The
welding procedures will be prepared by the erection contractor
and approved by TKF.
Welding seams that have to be checked by ULTRASONIC are
designated on the drawings and the test schedules!

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 PLANT: GAC GUINEA BAUXITE HANDLING PROJECT tkII– No.
West Africa
SPCPL: Barge Loader 001

ERECTION MANUAL

3.2 Sub Structure

Sub Structure
Slewing connection

First the Sub Structure part has to be lifted into its final
position, adjusted with shim plates and mounted
(t i g h t e n i n g torques) to the anchor bolts on the
foundation.

Afterwards the slewing connection (bearing ) will be

installed.

 Note: Take care to the position of the hardness

gap. Installation and tightening torque
have to be executed in accordance to the
Respective manual (see hereto O&M
Manual ).

After tightening the screws the locking caps filled with

grease have to be installed.

Weights:
Sub Structure approx. 3 7 0 0 0 kg
Slewing connection approx. kg

3.3 Slew Deck

Slewing part ( Slew Deck )

Now the Slew Deck has to be lifted, adjusted and

connected to the slewing bearing.

 Note: Take care to the position of the hardness

gap. Installation and tightening torque
have to be executed in accordance to the
respective manual ( see hereto O&M
Manual ).

Weight:
Slew Deck approx.88,000 kg

ment shared for reference

 PLANT: GAC GUINEA BAUXITE HANDLING PROJECT tkII– No.
West Africa
SPCPL: Barge Loader 001

ERECTION MANUAL

3.4 Hoisting Cylinder

Hinge point – hydraulic cylinder

Hydraulic cylinder ( hoist )

After installation of the Slew Deck, the hoisting

cylinder has to be installed, supported and fixed with
staying ropes against tilting and moving. The
cylinder has to be filled with oil, air extracted,
bypassed and retracted. (see hereto Hydraulic
Manual ).

Weight:
Hydraulic cylinder approx. 2.800 kg

3.5 Main Boom with Shuttle

( Constr. group 74000 )

Transport Sketch
Arrangement boom/shuttle
Arrangement Ship Loader
Hinge point – boom conveyor
Erection support sketch

Preconditions:
The boom has to be assembled with all mechanical parts, necessary for installation of the
shuttle.

A temporary erection support has to be positioned on the pier to support the boom during
erection until the counterweights are installed and the hoisting system is ready for operation
(s e e hereto erection support sketch).

The direction of the hinge point axis of the boom ( Slew Deck ) must be rectangular to the pier
and the storm locking device to be installed and locked.

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 PLANT: GAC GUINEA BAUXITE HANDLING PROJECT tkII– No.
West Africa
SPCPL: Barge Loader 001

ERECTION MANUAL

Lifting sequence:
When the preconditions are satisfied the boom can be lifted (in horizontal position) and
placed between the hinge points of the Slew Deck.

The two pins will be inserted into the hinge points.

When the pins have reached their final position, the boom can be lowered onto the erection
support and fixed with staying ropes.

After lowering the boom onto the erection support, the crane can be released.

ment shared for reference

 PLANT: GAC GUINEA BAUXITE HANDLING PROJECT tkII– No.
West Africa
SPCPL: Barge Loader 001

ERECTION MANUAL

After installation, the shuttle has to be completely retracted and locked, to avoid an extending
of the shuttle during erection works.

The boom incl. shuttle can be completed now with all remaining mechanical items, as well as
the electrical installation.

 Note: Special attention has to be paid to the correct tightening of the shrink disc of the
hinge pins. ( See hereto O&M Manual ).
Weights:
Boom ( steel structure only ) approx. 200,000 kg
Shuttle ( steel structure only ) approx. 54,000 kg

Attention: If the mechanical items of the shuttle are installed prior lifting and
slotting procedure, the forces of the erection support rises up to
approx. XXXXkN ( each girder ) see erection support sketch!

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 PLANT: GAC GUINEA BAUXITE HANDLING PROJECT tkII– No.
West Africa
SPCPL: Barge Loader 001

ERECTION MANUAL

3.6 Hydraulic system

Hydraulic piping layout

Stairs and railing

The following works can be executed partly parallel.

The support for the hydraulic unit has to be installed ( it contains to the stairs and railing of the
Slew Deck ). Afterwards the hydraulic power pack has to be installed.

The hydraulic motor with gear box has to be installed, adjusted and tightened in accordance
with the respective manual.

The hoses and pipes for the hydraulic motor as well as for the hoisting cylinder have to be
installed.

Attention: In no case, hot bending of hydraulic pipes will be acceptable only

cold bending or fittings are allowed. Also after cutting, the pipe
ends have be smoothly ground, trimmed and blown out by
compressed air, prior installation. ( See also Hydraulic Manual )

After installation of the hydraulic systems they have to be flushed and air extracted before
setting in operation.

 Note: The flushing of the hydraulic systems has to be executed by using a temporary
bypass filter system with an independent pump. The hydraulic system has to be
flushed in the presence of a ThyssenKrupp-advisor! ( See Hydraulic Manual )

After set in operation of the hydraulic system, the hoisting cylinder has to be connected to the
boom.

Weight:
Hydraulic power pack approx. 900 kg

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 PLANT: GAC GUINEA BAUXITE HANDLING PROJECT tkII– No.
West Africa
SPCPL: Barge Loader 001

ERECTION MANUAL

3.7 Electrical Equipment

Arrangement of electrical equipment

The cabling and electrical equipment will be installed parallel to the mechanical erection.

3.8 Counterweight

Boom counterweight

Preconditions of balancing procedure:

The boom must be completely erected including all mechanical and electrical items. The belt
must be pulled and spliced. The luffing cylinder must be hydraulically blocked and ready for
operation. The complete boom should be free of any additional weight and tools and is not
fixed with the auxiliary support.

During the balancing procedure no erection tools, scaffolding material etc. should remain
around the boom.

The balancing procedure should be carried out with a minimum of wind influences.

Balancing procedure:
Two pressure gauges ( glycerine absorbed ) with a measuring accuracy of 1% or better have
to be connected to the control block measuring points, rod side and piston side, at the
hydraulic cylinder. Hydraulic cylinder has to be checked for a proper function.

Attention has to be paid to place the counterweight blocks shock less onto the boom back part.
The counterweights have to be inserted step by step.

For the theoretical counterweight please refer to counterweight drawing. It has assumed that
the final weight of the counterweights has been checked by weighing and the copies of the
weighing cards/protocol been submitted to TKF upon the weighing operation.

The measurement schedule of the forces in the boom hoisting cylinder during balancing
procedure shall be submitted immediately to ThyssenKrupp for checking.

The remaining counterweights have to be installed until correct pressure values of luffing
cylinder are achieved in accordance to the “Control of the forces in the hydraulic cylinder of the
boom”. (Document is attached to chapter 3)

A further adjusting of the counterweights may become necessary as a result of the final
verification by our Engineers.

Counterweight has to be erected under the instructions of the ThyssenKrupp (TAG) advisor.

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 PLANT: GAC GUINEA BAUXITE HANDLING PROJECT tkII– No.
West Africa
SPCPL: Barge Loader 001

ERECTION MANUAL

After balancing, the boom should be lifted or lowered to all relevant positions and pressure in
the hydraulic cylinder will be checked and transmitted to ThyssenKrupp.

 Note: See also the O&M Manual.

Weight:
Counterweight each single part approx. 74,000 kg

3.9 Ladders, Railings and Platforms

Stairs form +3.000 to 10.410

Round platform
Stairs and railing

The installation of the ladders, railings and platforms will be executed parallel to the
mechanical erection and electrical installation.

Weight:
Round platform ( 4 peaces ) each approx. 1.100 kg

3.10 Lubrication

Lubrication plan – slewing gear

Lubrication runner wheels

The pre-installed lubrication systems have to be completed parallel to the mechanical /

electrical erection and will be executed in accordance with the relevant standards, drawings,
safety regulations and technical specifications. ( See hereto O&M Manual )

ment shared for reference

 PLANT: GAC GUINEA BAUXITE HANDLING PROJECT tkII– No.
West Africa
SPCPL: Barge Loader 001

ERECTION MANUAL

3.11 Completion of the BL

Following individual parts, structures and components have to be installed, respectively to be

completed, after or during the erection of each main component according to their relevant
drawings.

- Transfer chute of the feeding conveyor

- Platforms, accesses, walkways and handrails
- Fitting of the remaining gratings
- Material skirting
- Wind protection
- Supports for switches
- Installation of lighting and lightening, switch gears, etc. according to the electrical manual
- Touch-up painting
- Etc.

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