Method Satement
Method Satement
Method Satement
Girder Installation
TABLE OF CONTENT
ARTICLE
Purpose
Scope of work
Reference Documents
Lifting Equipment
Work Sequence
Procedure
Lifting Plan
ATTACHMENTS
Appendix A
Drawing 30530-C-B3451 – Platform EL. 59.460 T.O.S. between Axes (B7 & B4)
Appendix B
Appendix D
Job Hazard Analysis
1. PURPOSE
This method statement is to describe a work explanation of the method to be carried out
during the heavy girder installation work such as material unloading, material check,
preparation for lifting, lifting, installation, for Suez Thermal PP 1x650MW Project, to
ensure that during the entire execution stage the work is done in line with good
engineering practices and is compliance with engineering standard practices, nation &
local codes, and project procedures, specifications.
2. SCOPE OF WORK
Installation preparation for lifting, lifting, installation of Heavy Girders “Two piece”.
3. REFERENCE DOCUMENTS
Erection drawing No. 30530-C-B3451 – Platform EL. 59.460 T.O.S. between Axes (B7 & B4).
Shop Drawing No. “Appendix A”
4. LIFTING EQUIPMENT
All Lifting Equipment which will be used shall be inspected and certified by qualified party.
The main tools & equipment for Heavy Girder use are as follows:
Crawler crane 500 T 1 Set ( For lifting )
5. Work Sequence
5.1 The Calculations for lifting “ Appendix B”
6. Procedure
Lifting Heavy Girder from Assembly area to Boiler area by crawler crane 500 tons.
Appendix A
Drawing 30530-C-B3451 – Platform EL. 59.460 T.O.S. between Axes (B7 & B4)
Appendix B
Bevel Angle of Lifting Lug Calculations
Heavy girder Center of Gravity Calculation
Heavy girder Life Line Calculations
Wire Rope Data Sheet for Life Line
Scaffolding Calculations of Heavy Girders
DEFINITIONS
L= Span = Bigest length of scaffolding ( Pipe & Wood ) , L= 100 CM
d= scaffolding pipes Diameter = 48.3 mm= 4.83 CM
t= scaffolding pipes Thick 3.2 mm= 0.32 CM
A= scaffolding pipes cross section = 2∏*d*t = 9.7152 cm²
P= The average weight of person = 150 Kg
S= The others weights as tools …Etc = 20 Kg
K=The Number of persons will use the life line,K = 3
F=Impact Factor = 1.2
R = Safe factor = 3
W=K*(P+s)*F*R , The weights which were loaded to the Scaffolding, W= 1,836.00 Kg
σ=My/I
y=d/2= 2.415 CM
4
I=∏(d/2)⁴- ( (d-t)/2)⁴/4 Cm = 185.445 Cm4
B.MKgCm
22,950.00 = <<< M= 125,319.36 KgCm DESIGN O.K.
1-B
Maximum bending moment
NMB.M= WL
B.M=
91,800.00 KgCm
σ=My/I
y=d/2= 2.415 CM
I=∏(d/2)⁴- ( (d-t)/2)⁴/4 Cm4 = 185.445 Cm4
B.MKgCm
91,800.00 = <<< M= 125,319.36 KgCm DESIGN O.K.
Eng.Ahmed Salama
Tech.Office Manager
Misr Co. for Mech. & Elect. Projects (KAHROMIKA ) Tech.Office
Power Plants Sector
Suez Thermal Power Plant (650MW x 1 Unis) Contract- CP - 105
Scaffolding calculations
* The critical scaffolding will be at the bigest span so our calculation will be for the bigest span 1 M "1000 mm"
250 mm
50
m
m
DEFINITIONS
L= Span = Bigest length of scaffolding ( Pipe & Wood ) , L= 100 CM
d= Wood sheet width = 250 mm= 25 CM
t= Wood sheet Thick 50 mm= 5 CM
A= scaffolding pipes cross section = d*t = 125 cm²
P= The average weight of person = 150 Kg
S= The others weights as tools …Etc = 20 Kg
K=The Number of persons will use the life line,K = 3
F=Impact Factor = 1.2
R = Safe factor = 3
W=K*(P+s)*F*R , The weights which were loaded to the Scaffolding, W= 1,836.00 Kg
σ=My/I
y=t/2= 2.5 CM
I=d*t³/12 cm4 = 260.417 Cm4
22,950.00B.M =
KgCm <<< M= 45,625.00 KgCm DESIGN O.K.
Eng.Ahmed Salama
Tech.Office Manager
Misr Co. for Mech. & Elect. Projects (KAHROMIKA ) Tech.Office
Power Plants Sector
Suez Thermal Power Plant (650MW x 1 Unis) Contract- CP - 105
Scaffolding calculations
* The critical scaffolding will be at the bigest span so our calculation will be for the bigest span 1 M "1000 mm"
3- The load effect on the scaffolding fittings " scaffolding connections together"
DEFINITIONS
L= Span = Bigest length of scaffolding ( Pipe & Wood ) , L= 100 CM
d= Wood sheet width = 250 mm= 25 CM
t= Wood sheet Thick 50 mm= 5 CM
A= scaffolding pipes cross section = d *t = 125 cm²
P= The average weight of person = 150 Kg
S= The others weights as tools …Etc = 20 Kg
K=The Number of persons will use the life line,K = 3
F=Impact Factor = 1.2
R = Safe factor = 3
W=K*(P+s)*F*R , The weights which were loaded to the Scaffolding, W= 1,836.00 Kg
3- The load effect on the scaffolding fittings " scaffolding connections together"
The effect of load in the two connection points will be W/2 = 8.9964 KN
Scaffolding calculations
4- The load effect on the scaffolding fittings " scaffolding connections with columns"
DEFINITIONS
L= Span = Bigest length of scaffolding ( Pipe & Wood ) , L= 100 CM
d= Wood sheet width = 250 mm= 25 CM
t= Wood sheet Thick 50 mm= 5 CM
A= scaffolding pipes cross section = d*t = 125 cm²
P= The average weight of person = 150 Kg
S= The others weights as tools …Etc = 20 Kg
K=The Number of persons will use the life line,K = 3
F=Impact Factor = 1.2
R = Safe factor = 3
W=K*(P+s)*F*R , The weights which were loaded to the Scaffolding, W= 1,836.00 Kg
4- The load effect on the scaffolding fittings " scaffolding connections with columns"
The effect of load in the two connection points will be W/2 = 8.9964 KN
D
L
A2
C
V A3
T
W
Giveg data & Definitions A4
P loading N (Kg* 9.8)
τ = Allowable shear stress = 0.35 x Yield stress.
Yield stress. =250 N/mm²
Safety factor = F
D Diameter of Shackles pin
There are four area will be sujected to the load by shear stress ,so the calculation will study this areas
T
1- A1= S* T 2- A2 = T*(W-D)
τ= P/A
τ= P/A= P/ST D
S
T= P/Sτ
T= P/(τ(w-D))
τ= P/A= P/VT V T
V= P/Tτ
N
W
The welding shape K
τ= P/2N(W+T) N= K * Cos 45
τ= P/( 2K * Cos 45*(W+T))
W=(P/2K * Cos 45*τ)-T
The calculations with 1.5 Safety factor
The dimensions
Case No.
P D T W C V L S K
8 9 1/2 93,100 1 1/2 38 1 1/9 28 4 2/5 112 2 53 1 1/3 33 4 1/4 108 1 4/9 37 1/2 13
9 12 117,600 1 5/8 41 1 1/9 28 5 126 2 1/5 56 1 2/5 35 4 2/3 119 1 2/3 42 1/2 13
10 13.50 132,300 1 3/4 44 1 1/9 28 5 2/9 133 2 1/2 63 1 3/5 41 5 129 1 3/4 44 1/2 13
11 17 166,600 1 5/6 46 1 1/9 28 5 1/2 140 2 5/8 66 1 5/7 43 5 3/8 136 1 5/6 47 1/2 13
13 35 343,000 2 1/2 64 1 2/3 42 7 5/7 196 4 2/5 112 3 1/7 80 8 1/4 210 2 3/5 66 7/8 22
P A1 A2 A3 A4
2 1 1/2 14,700 1/4 160 1/2 319 3/7 281 1 1/6 753
4 3 3/4 36,750 4/9 290 1 2/9 785 5/7 466 1 3/4 1,129
6 6 1/2 63,700 1 1/8 727 2 1/4 1,455 1 1/8 727 3 1/9 2,007
7 8 1/2 83,300 1 1/3 876 2 5/7 1,753 1 1/3 876 3 1/2 2,258
8 9 1/2 93,100 1 3/5 1,029 3 1/5 2,058 1 4/9 935 3 8/9 2,509
Note That :-
- This calculations depend on the metal which will use is Carbon Steel " ASTM 36 "
- The above dimensions can change but the cross section area of each area " A1&A2&A3 and A4" must be the same areas which were mentioned in the above table or more than
Eng.Ahmed Salama
Tech.Office Manager
Misr Co. for Mech. & Elect. Projects (KAHROMIKA ) Tech.Office
Power Plants Sector
Suez Thermal Power Plant (650MW x 1 Unis) Contract- CP - 105
26,796 mm
20mm
20 Cm
Detail A
W=K*P*F
δ= ϵ*L
σ=W/A
σ=Eϵ ϵ= σ/E
σ=W/A = 78.03 N/ mm² mm mm
so this value is within range of tensile strength L/2 = 6,449.00 L/2 = 6,449.00
δ= 17.11518 mm
β= 470.154 mm =
Tan Ɵ₁ = β /(L/2)= 0.072903354 Ɵ₁= Ɵ2 = 5.3 Degree
T₁=T₂
T₂ T₁
Σy=0 Ɵ2 Ɵ₁
MT= Max. tension in wire 12mm according to table "Attached A"= 9.25 tons =9.25*1000*9.8= 90,650 N
Note That :-
1- The rope will be fixed at each edge
2- The length of the L angle will be 1.1 M
3- The fixed point of the rope will at 1 M of L angle length and the other fixed point will be at 0.95 m of L angle length
L Angle N
L Angle
Fillet Weld Welding Area
L Angle N
τ= P/L*N N= K * Cos 45
τ= P/( K * Cos 45*L)
P= τ * ( K * Cos 45*L)
At
τ = Allowable shear stress = 0.35 x Yield stress.
Yield stress. =250 N/mm²
K= 6 mm τ= 87.5 L= 200 mm
After We check the L Angle Condition we found there are some holes in the top of the angle so , we will decrease the number of persons to 5 persons not 8 persons
We recommend that , the Number of persons will use the life line will be 5 persons for each rope or less
Eng.Ahmed Salama
Tech.Office Manager
Misr Co. for Mech. & Elect. Projects (KAHROMIKA )
Power Plants Sector
Suez Thermal Power Plant (650MW x 1 Unis) Contract- CP - 105
Site Tech. Office
Issue Date:- 4-May-14
Heavy girder Center of Gravity Calculation
Giveg data & Definitions
X 15.1 = the distance bteween the Center of Gravity of item G245015.1 and the Y axis " this is given " 3,835 mm
X 26.1 = the distance bteween the Center of Gravity of item G245026.1 and the Y axis " this is given " 13,348 mm
X 14.1 = the distance bteween the Center of Gravity of item G245014.1 and the Y axis " this is given " 22,140 mm
X = the distance bteween the Center of Gravity of total haevy girder and the Y axis " this is unknown "
W 15.1= the weight of item G245015.1 = 22,139 Kg
W 26.1= the weight of item G245026.1 = 29,462 Kg
W 14.1= the weight of item G245014.1 = 18,299 Kg
W = the total weight of the haevy gorder = 69,900 Kg
Fabricated Temporary Lugs
Y
22,140
X14.1
13,348
X26.1
3,835
X15.1
6,636
12,636
X
G245015.1 G245026.1 G245014.1
mm mm mm ∑
D
L
A2
C
V
A3
T
W
Giveg data & Definitions A4
P loading N (Kg* 9.8)
τ = Allowable shear stress = 0.35 x Yield stress.
Yield stress. =250 N/mm²
Safety factor = F
D Diameter of Shackles pin
T
N
W
The welding shape "Fillet Weld" K
τ= P/2N(W+T) N= K * Cos 45
τ= P/( 2K * Cos 45*(W+T))
W=(P/2K * Cos 45*τ)-T
P D T W C V L S K
τS = shear stress will be on the welding area = 48.82 << τ = Allowable shear stress = 87.5
Eng.Ahmed Salama
Tech.Office Manager
Method Statement for Heavy
Girder Installation
Appendix C
Lifting Plan No 43 &39
Lifting Plan Data Sheet
Issue Date: Sunday, May 25, 2014
Job No.: 0043
Project: SUEZ THERMAL POWER PLANT 650 MW
Lift Company: KAHROMIKA
Load Name: Heavy Girder
Load Description: Lifting Heavy Girder on Position
1‐ Rigging Bill Of Materials
Description Serial Number Quantity Wt/each Weight Unit
Wire Rope Sling (3"*12M) 62 Ton 2 0.312 0.624 Tons
Shackels 55 Ton 2 0.085 0.170 Tons
Lifting Lug 50 Ton N.A. 2 0.131 0.263 Tons
Hook Block Weight N.A. 1 10.800 10.800 Tons
0.000 Tons
0.000 Tons
0.000 Tons
Rigging Tools Total Weight 11.857 Tons
2‐ Calculation for Main Crane: DEMAG CC 2500‐1 500 Tons (SWSL)
Package Package Package & Rigging Tools Radius/M Boom Length
Chart Capacity/Ton % of Capacity Used
Name/No Weight/Ton Weight/Ton Actual Chart M. Boom Fly Jib
First Radius R1
Main Girder 69.9 81.8 24.7 26 60 36 104 79%
Second Radius R2
Main Girder 69.9 81.8 26 26 60 36 104 79%
3‐ Calculation for Auxiliary Crane:
Package Name Package Total Wight Crane Radius Boom Length Chart Capacity % of Capacity Used
Main Girder
Notes: Attach Sketch showing Plan & Elevation .Attach relevant Crane chart extract
See Attached
Lifting Plan Data Sheet
Issue Date: Sunday, May 25, 2014
Job No.: 0039
Project: SUEZ THERMAL POWER PLANT 650 MW
Lift Company: KAHROMIKA
Load Name: Lifting Plan For Heavy Girder
Load Description: Shifting The Heavy Girder from assembly area to lifting area
1‐ Rigging Bill Of Materials
Description Serial Number Quantity Wt/each Weight Unit
Wire Rope Sling (3"*12M) 62 Ton 2 0.312 0.624 Tons
Shackels 55 Ton 2 0.085 0.170 Tons
Lifting Lug 50 Ton N.A. 2 0.131 0.263 Tons
Hook Block Weight N.A. 1 10.800 10.800 Tons
0.000 Tons
0.000 Tons
0.000 Tons
Rigging Tools Total Weight 11.857 Tons
2‐ Calculation for Main Crane: DEMAG CC 2500‐1 500 Tons (SWSL) without Superlift
Package Package Package & Rigging Tools Radius/M Boom Length
Chart Capacity/Ton % of Capacity Used
Name/No Weight/Ton Weight/Ton Actual Chart M. Boom Fly Jib
Main Girder 69.9 81.8 20 20 60 36 102 80%
3‐ Calculation for Auxiliary Crane:
Package Name Package Total Wight Crane Radius Boom Length Chart Capacity % of Capacity Used
Main Girder
Notes: Attach Sketch showing Plan & Elevation .Attach relevant Crane chart extract
See Attached
Appendix D
Job Hazard Analysis