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Recovery of Damaged Lock Gate
- 2. Recovery of Gladstone Gate 1 Description 2 Initial Concept 3 Solution 4 Refining Solution 5 Design Method 6 Fabrication 7 Lift 8 Lessons Learned 9 Questions & Answers Introduction
- 3. Recovery of Gladstone Gate • The gate was subsequently recovered & put in temporary storage • Temporary measures to bring port back into operation • The gate was damaged & required repairing • Removal from the dock was required • Solution for gate removal from the dock to be developed In January 2004 operations at the Port of Liverpool were brought to a halt, when, during a storm one of the lock gates at Gladstone dock was ripped from its hinges.
- 4. Recovery of Gladstone Gate
- 5. Recovery of Gladstone Gate
- 6. Recovery of Gladstone Gate Height 17 600 mm Breadth 21 952 mm Depth 2 400 mm Weight 393 tonnes Details of Gate`
- 7. Recovery of Gladstone Gate Gladstone Dock Gate London Bus
- 8. Recovery of Gladstone Gate
- 9. Recovery of Gladstone Gate
- 10. Recovery of Gladstone Gate
- 11. Recovery of Gladstone Gate Initial Concept Initial feasibility undertaken by MDHC Options considered •Conventional repair using dry dock •Conventional lift of gate using crane •Tipping cradle
- 12. Recovery of Gladstone Gate Conventional repair using dry dock • Condition of gate below water line unknown • Availability of dry dock
- 13. Recovery of Gladstone Gate Conventional lift using cranes • Weight & size of gate would require a tandem lift using two 1000 tonne cranes • Availability of space to accommodate the footprint
- 14. Recovery of Gladstone Gate Tipping Cradle
- 15. Recovery of Gladstone Gate Tipping Cradle • Distinct advantages to MDHC • Mersey Mammoth floating crane could be used (250 t capacity) • Wholly owned by MDHC • Another 5 gates require refurbishment • cradle could be reused
- 16. Recovery of Gladstone Gate 400t 250 t 184 t BuoyancyTotal Lift 400-184=216 t max
- 17. Recovery of Gladstone Gate Initial Option Use of Mersey Mammoth to rotate gate and pull it onto quay side 230 tonne of kentledge required Requirement to rotate gate from bottom
- 18. Recovery of Gladstone Gate What to do when gate is horizontal Two options considered • Slide gate onto quay side • Provide vertical support at end of cradle • Enter the Camel
- 19. Recovery of Gladstone Gate What is “The Camel” • Floating barge Used to salvage vessels • Built circa 1958 • Length 104’ (42.67m) • Beam 35’ (10.67 m) • Owned by MDHC • Laid-Up for 3-4 years • Therefore no cost on project & ideal for use
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- 21. Recovery of Gladstone Gate
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- 23. Recovery of Gladstone Gate Problems With Using Camel • Floating vessel • Age – Unknown condition • No access to inside for condition survey • Fuel on board – No possibility of welding to deck
- 24. Recovery of Gladstone Gate Problems With Using Camel • Floating vessel Design calculations • Age – Unknown condition Lloyds survey • No access to inside for condition survey Lloyds survey • Fuel on board – No possibility of welding to deck Clamped connection to bollards
- 25. Recovery of Gladstone Gate Details of Camel Bollard Clamp
- 26. Recovery of Gladstone Gate Preferred solution • Use tipping cradle to recover gate • Mersey Mammoth used to lift cradle • Camel used to support gate during repairs
- 27. Recovery of Gladstone Gate Tipping Cradle
- 28. Recovery of Gladstone Gate Design Method • Very good drawings of gate available • Strength an condition of dock wall uncertain • Good Guide to gate weights & CoG’s • Uncertainty on gate condition Amount of leakage Amount of entrained silt • Trial lift required
- 29. Recovery of Gladstone Gate Trial Lift • Trial lift undertaken May 2005 • Results inconclusive – Gate appears heavier than drawing weight • Further investigation revealed gate was not emptied of all water for trial. • Gate reported as being clear of silt • 2nd trial lift not possible during design • Uncertainty as to reason for excess weight
- 30. Recovery of Gladstone Gate Design Brief • To cater for uncertainty of gate weight 50 tonne allowance • 60% / 40% split in load to cater for 1.Uneven distribution in load 2. Incorrect position of gate in cradle • Upper & lower bound load cases defined • Upper bound – Used for member design & lifting loads • Lower bound – Used for lifting loads • Stability and strength of dock wall by assessment • Lateral load resisted by shear key in foundations
- 31. Recovery of Gladstone Gate Gate Prior to Rotation Gate in Final Position
- 32. Recovery of Gladstone Gate
- 33. Recovery of Gladstone Gate 171 te 83 te 72 te 75 te 100 te 74 te 329 te 201 te 230 te 195 te 168 te 142 te 0 te 50 te 100 te 150 te 200 te 250 te 300 te 350 te 400 te 450 te 0 10 20 30 40 50 60 70 80 90 100 Angle of Rotation MammothLoad Upper Bound Vertical Mammoth Load Lower Bound Vertical Mammoth Load High Predicted load on Mammoth not including Buoyancy Low Predicted load on Mammoth including Buoyancy
- 34. Recovery of Gladstone Gate Design Brief • 250 tonne capacity of Mammoth not sufficient to rotate gate from vertical • Additional lifting capacity required • Additional capacity should provide horizontal pull • Use of tugs to start lift • Mammoth to complete lift • Foundations provided remote from quay edge to take lateral loads
- 35. Recovery of Gladstone Gate
- 36. Recovery of Gladstone Gate Method of Analysis Simple 2D STAAD Pro models for various configurations Vertical, 10°,22.5°, 33.75°, 45°, 67.5, 90° Various configurations •Gate against wall •Gate supported on Mammoth •Gate supported on tug •Gate supported on Camel (final condition)
- 37. Recovery of Gladstone Gate Testing Requirements • Two types of testing • NDT of welds • Load testing of critical items
- 38. Recovery of Gladstone Gate Testing Requirements NDT of welds • Many full penetration weld in highly loaded areas • No redundant load path in these areas • All full pen welds 100% MPI & 100% UT
- 39. Recovery of Gladstone Gate Main Pin Detail No positive connection to coping
- 40. Recovery of Gladstone Gate Main Pin Detail
- 41. Recovery of Gladstone Gate Testing Requirements LOLER Requirements REGULATION 9 -THOROUGH EXAMINATION AND INSPECTION Load testing to confirm the build quality and structural load bearing capability of the lifting equipment Functional and operational envelope tests to verify the satisfactory working range of the lifting equipment. Testing of lifting equipment should be undertaken at the discretion of the competent person .
- 42. Recovery of Gladstone Gate Testing Requirements Load test of critical items Discussions with HSE • Main pin assembly • Tug lifting eye • Mammoth lifting eye
- 43. Recovery of Gladstone Gate Testing Requirements Load test of critical items Programme & cost implications •Test main pin assemblies only •Full NDT of all components of Lifting Eyes •Measures taken to ensure no person under the shadow of the lift •For design of lift items FoS = 2.0 •For load test proof load = 1.5
- 44. Recovery of Gladstone Gate Testing Frame for Main Pin
- 45. Recovery of Gladstone Gate Testing Frame for Main Pin
- 46. Recovery of Gladstone Gate Testing Frame for Main Pin
- 47. Recovery of Gladstone Gate
- 48. Recovery of Gladstone Gate
- 49. Recovery of Gladstone Gate Lifting of Gate
- 50. Recovery of Gladstone Gate
- 51. Recovery of Gladstone Gate
- 52. Recovery of Gladstone Gate
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- 55. Recovery of Gladstone Gate
- 56. Recovery of Gladstone Gate
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- 59. Recovery of Gladstone Gate
- 60. Recovery of Gladstone Gate
- 61. Recovery of Gladstone Gate
- 62. Recovery of Gladstone Gate
- 63. Recovery of Gladstone Gate
- 64. Recovery of Gladstone Gate
- 65. Recovery of Gladstone Gate
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- 67. Recovery of Gladstone Gate
- 68. Recovery of Gladstone Gate
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- 70. Recovery of Gladstone Gate
- 71. Recovery of Gladstone Gate
- 72. Recovery of Gladstone Gate
- 73. Recovery of Gladstone Gate
- 74. Recovery of Gladstone Gate
- 75. Recovery of Gladstone Gate Lessons Learned
- 76. Recovery of Gladstone Gate Test requirements and impact Tightening of clamp assemblies Use of Camel Lessons Learned
- 77. Recovery of Gladstone Gate Questions & Answers