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Lifting plan for inlet duct removal

This lifting plan details the procedures and equipment for removing three inlet ducts (DT#01, DT#02, DT#03) from a power plant using two cranes. A 150-ton crawler crane will lift each duct while being repositioned and swung by the crane operator. A trailing 70-ton crane will assist in lowering the ducts onto a trailer. Rigging diagrams and specifications are provided for the cranes and accessories like spreader beams, wire slings, and chain blocks. Each duct will be lifted to a certain height, moved sideways and backed out of place before being lowered onto the trailer.

Engineering◦
2014 Prepared by Md. Shaha Jalal Mechanical Maintenance Technician A large multinational power generation company Lifting Plan for Inlet Duct removal
Lifting Plan for Inlet duct Tools & equipment to be used: i. Manitowoc 4000 W Vicon Crawler Crane : 1 no. Purpose : To lift the load. Capacity : 150 ton ii. P&H (70 ton capacity) Crane (trailing crane) : 1 no. Purpose : To trail the load. Capacity : 70 ton iii. Trailer with Prime Mover. : 1 no. Purpose : To shift the load. Capacity : 50 ton Length : 20 m (65 feet) Width : 10 m (33 feet) iv. Chain Blocks : 3 nos. Purpose : To balance the load Capacity : 15 ton v. D-Shackles ,35 ton : 8 nos vi. D-Shackles ,25 ton : 4 nos vii. Wire Rope , 20 ton, length- 3 m (10 feet) : 16 nos viii. Wire Rope , 20 ton, length- 4 m (13 feet) : 8 nos ix. Wire Rope , 20 ton, length- 5 m(15 feet) : 16 nos x. Wire Rope , 20 ton, length- 6 m(26 feet) : 8 nos xi. Wire Rope , 20 ton, length- 9 m(30 feet) : 8 nos xii. Spreader Beam : 2 no. xiii. Hydraulic Jack, 100 ton : 4nos xiv. Nylon Rope (Tag Line) – Diameter 1 inch : 2 rolls xv. Warning Tape : 2 rolls xvi. Walkie -Talkie System of same channel : 4 sets
Rigging Drawing for Lifting of Duct with 150 ton Crawler crane. Specification of crane: Load capacity (Max) : 150 ton Boom Length : 130 feet Counter Weight : 104.4 klb Distance from mass center of the load : 11.5 m (38 ft) Angle of boom : 73 degree. Specifications of rigging accessories: Spreader Beam: Safe working load : 42 ton Length : 8400 mm (27.552 ft) Width : 219 mm (8.61 Inc.) Required Quantity : 2 Nos Chain Block: Capacity : 15 ton Required Quantity : 2 nos + 1 spare Lifting lug: As per Appendix: 01 Wire sling: Capacity Length Qty 20 ton 3843 mm (13’) 02 20 ton 4500 mm(15’) 04 20 ton 8100 mm(26’) 02 Nylon Rope 1’’ --- 1 roll
Detail Arrangement: All rigging accessories will be arranged as per drawing shown below. Fig: Rigging arrangement for lifting DT#01
Lifting Procedure for DT#01: a. Place the 150 ton crane at 38 feet radius from the center line of the load. (annex:04) b. Hang the load with lifting accessories and lift up to 15 mm with the help of hydraulic jack at jacking position.( Annex:01) c. DT#01 will be lifted 42 ft from ground level. Boom Length : 130 ft Radius : 38 ft Angle of boom = Cos-1 (38ft/130ft) = 73 degree Available lifting height = 38 tan 73° = 124 ft Available lifting height: = 124 – Load height – Distance between touching point to boom top. = 124 – 35 – 47 = 42 ft Lifting accessories length: =37 ft Load Capacity : 40 ton (from load chart: annex 02) Load weight : 30 ton Accessories : 2 ton Total load weight : 32 ton
d. Slowly move the crane backward (north to south) until just before the load touches DT#02. e. Swing the boom towards clockwise direction until just before the load touches steam pipe rack. f. Repeat procedure: d and procedure: e until DT#01 is removed from the slot of inlet duct, so that the crane can be mobilized (north to south) towards the trailer. g. When the crane comes at a position in line with EDG (emergency diesel generator), annex#04 and boom will be swung 180 degree clockwise to lay down on trailer with the help of trailing crane. h. Place the trailing crane beside (east side of trailer) and in line (east to west) with trailer. i. Hook up the trailing crane to lower lug with the help of wire sling as shown in the below arrangement. Fig: Rigging arrangement of trailer crane and main crane.
j. The load will be tilted down by lowering the main crane and lifting up the trailing crane as shown in the below figure. Figure: Load placement on trailer. k. Trailer will be placed underneath the load and load will be put on the trailer bed. l. Trailer will be moved to storage area. m. In the storage area, DT#01 will be unloaded by two cranes (100 ton and 70 ton). Lifting Procedure for DT#02: a. Place the 150 ton crane from the center line of the load. (annex:04) b. Hang the load with lifting accessories and lift up to 15 mm with the help of hydraulic jack at jacking position.( Annex:01) c. DT#02 will be lifted to 25 ft from ground level.
Figure: Lifting of DT#02 Boom Length : 130 ft Radius : 38 ft Angle of boom = Cos-1 (38ft/130ft) = 73 degree Available lifting height = 38 tan 73° = 124 ft Available lifting height: = 124 – Load height – Distance between touching point to boom top. = 124 – 49 – 50 = 25 ft Load Capacity : 37 ton (from load chart: annex 02) Load weight : 28 ton Accessories : 2 ton Total load weight : 30 ton Lifting accessories length= 37 ft
d. Swing the boom towards clockwise direction and will stop the crane just before when load will touch the Gas turbine diffuser. e. Slowly move the crane backward (north to south) just before the load touches DT#03. f. Repeat procedure: d and procedure: e until DT#02 will be fully removed from the slot of inlet duct, so that the crane can be mobilized (north to south) towards the trailer. g. When the crane will come at a position in line with EDG ( emergency diesel generator), boom will be swung 180 degree clockwise to lay down on trailer with the help of trailing crane. h. Place the trailing crane beside (east side of trailer) and in line (east to west) with trailer as shown for DT#01. i. Hook up the trailing crane to lower lug with the help of wire sling. j. The load will be tilted down by lowering the main crane and lifting up the trailing crane as shown for DT#01. k. Trailer will be placed underneath the load and load will be put on the trailer bed. l. Trailer will be moved to storage area. m. In the storage area, DT#02 will be unloaded by two cranes (100 ton and 70 ton). Lifting Procedure for DT#03: a. Place the 150 ton crane from the center line of the load. (annex:04) Figure: Lifting of DT#03 b. Hang the load with lifting accessories and lift up to 15 mm with the help of hydraulic jack at jacking position.( Annex:03) c. DT#03 will be lifted 3.5 ft from ground level. Boom Length : 130 ft Radius : 38 ft Angle of boom = Cos-1 (38ft/130ft) = 73 degree Available lifting height = 38 tan 73° = 124 ft
d. Slowly swing the crane clockwise (west to east) and will stop the crane just before when load will touch the Gas turbine diffuser. e. Swing the boom towards clockwise direction until the load become in line with the road. f. Slowly move the crane backward (north to south), so that the crane can be mobilized (north to south) towards the trailer. g. Load will be laid down on trailer with the help of trailing crane. h. Place the trailing crane beside (east side of trailer) and in line (east to west) with trailer as shown in the below arrangement same as DT#01. i. Hook up the trailing crane to lower lug with the help of wire sling. j. The load will be tilted down by lowering the main crane and lifting up the trailing crane as shown for DT#01. k. Trailer will be placed underneath the load and load will be put on the trailer bed. l. Trailer will be moved to storage area. m. In the storage area, DT#01 will be unloaded by two cranes (100 ton and 70 ton). Available lifting height: = 124 – Load height – Distance between touching point to boom top. = 124 – 68 – 52.5 =3.5ft Lifting accessories length= 38.3 ft Load Capacity : 40 ton (from load chart: annex 02) Load weight : 35 ton Accessories : 2 ton Total load weight : 37 ton
Appendix-01: Figure: Spreader beam with lifting lug. Annex-01: Table: list of lifting accessories for DT#01 & DT#02 Name Size Qty. Wire Sling 20 ton x 13 ft 4pcs Wire Sling 20 ton x 15 ft 4pcs Wire Sling 20 ton x 26 ft 4pcs Spreader beam 8400 mm x 219mm 1pc Chain block 15 ton 2pcs Shackle 35 ton 4pcs
Figure: Jacking Points of inlet Duct. Annex-02: Table-01: Load chart for 150 ton crane.
Table -02: Load chart of 70 ton crane. Annex-03: Name Size Qty. Wire Sling 20 ton x 14 ft 4pcs Wire Sling 20 ton x 15 ft 4pcs Wire Sling 20 ton x 26 ft 4pcs Spreader beam 8.100 m x 219mm 1pc Chain block 15 ton 2pcs Shackle 35 ton 6pcs Table: lifting accessories for DT#03
Annex:04