Method of Statement of CC1800 Crane

METHOD
STATEMENT
ASSEMBLY
PROCEDURE CRANE
CC-1800
Burullus 4800 MW Combined Cycle Power Plant Project

Orascom Construction
OED
May, 2016
Contents
1 Introduction
1.1 INTRODUCTION TO THIS MANUAL 2

1.2 WEIGHTS OF THE MAIN COMPONENTS 2
2 Scope of Work
2.1 SUMMARY OF WORK SCOPE 3
3 ERECTING OPERATIONS
3.1 CONDITIONS FOR LIFTING 3

3.2 CRANE CONFIGURATION 3
3.3 BASIC CRANE DIMENSIONS 4
3.4 SUPPORT EQUIPMENT 5
3.5 LINE OF COMMAND 5
3.6 PRE LIFT CHECKS 6
3.7 COMMUNICATION 6
4 ERECTING PROCEDURE FOR CC-1800
4.1 SITE DATA 7

4.2 DELIVERY OF SUPERSTURCTURE 7
4.3 CRAWLERS ASSEMBLY 8
4.4 INSTALLING SUPERSTRUCTURE COUNTERWEIGHT 9
4.5 ASSEMBLY OF SUPER-LIFT MAST 10
4.6 ASSEMBLY OF MAIN BOOM 11
5 Procedures for Crane Disassembling 12
6 Weather conditions 13
1
1 Introduction
1.1 INTRODUCTION TO THIS MANUAL

The purpose of this document is to provide engineering and planning data to enable the
safe and efficient assembly and erection of the CC-1800 DEMAG and to verify that all
reasonable considerations have been taken. This document has been originated by
Orascom and refers essentially to their scope of work.
1.2 WEIGHTS OF THE MAIN COMPONENTS

 Total weight incl. 120 t counterweight and central ballast 30 t, 18 m SH boom and
hook block 259 t
 Superstructure (with 2 winches, A-frame) 29.6 t
 Carbody without jacks 14.5 t
 Carbody with track shoes 16.5 t
 Crawlers with pads 2×24 t
2 Scope of Work
2.1 SUMMARY OF WORK SCOPE

 Delivery of 1800-CC DEMAG components to assembly location
 Assembly of 1800-CC DEMAG
3 ERECTING OPERATIONS
3.1 CONDITIONS FOR LIFTING
The site lifting area is to be fully clear to allow the lifting operations to take place in a
safe and professional manner, without risk to those executing the operations and
others not directly involved with the lifting operations. All personnel not directly
concerned with the rigging, lifting and installation of the CC1800 components must
remain outside the barricaded working area.
3.2 CRANE CONFIGURATION
The CC-1800 will be erected in the following configuration:
DEMAG CC-1800 300t Crawler Crane (SSL)
Crawler Centers: 7.2 m

Main Boom Length: 18-72 m
Central Counterweight 30 t
Crane Counterweight: 120 t
 The assembly of the CC1800 will be the responsibility of the Orascom Superintendent he
will be in charge of directing the crane maneuvers and installation of the crane components.
The riggers will carry out all slinging operations under the direction of the Orascom
Superintendent.
 All personnel involved in the rigging operation shall wear personal protective equipment as
per site regulations and Orascom Safety Policy.
3.3 BASIC CRANE DIMENSIONS
3.4 SUPPORT EQUIPMENT
The assist cranes used are as follows:
RT- 9130 or Equivalent
3.5 Line of command
3.5.1 Organizational chart
Project
Manager
Engineering SHE-Q
Lifting
Supervisor
Crane
Riggers
Operator
3.5.2 Lifting supervisor
The lifting supervisor is in charge of the actual lifting operation.
3.5.3 Crane Operator
The crane operator ensures that all crane segments are checked and ready to execute the
task. The crane operator strictly follows the instructions of the supervisor and maintains
communication.
3.5.4 Riggers
The riggers check, attach and release rigging tackle. Besides that, the riggers can be the
extra eyes for the lifting supervisor and monitor clearances to obstacles and verify crane
operations.
3.6 Pre lift checks
Following things are checked prior to the lifting operation:
 Weather forecast.
 Correct crane setup during assembly
 Full compliance check list for crane operations
 Pre-lift toolbox meeting
 Rigging certificate overview
 Manbasket checklist + toolbox (in case of Manbasket operation).
3.7 Communications
Communications between Orascom supervisor and operators on site will be verbal; face
to face or by mobile phone.
4 ERECTING PROCEDURE FOR CC-1800
The following procedure is a guideline for the assembly of the CC-1800. The Orascom
Superintendent will be responsible for the assembly of the CC-1800 and has the authority to modify
the procedure order and make field changes as necessary as long as the site’s safety regulations and
the manufacturer’s recommendations are followed and the engineered lifting limitations are not
exceeded.
4.1 SITE DATA
The assembly of the CC-1800 crawler crane will be done in an open and leveled area at
the jobsite near to the lift-off positions. The ground must be fairly leveled and
compacted. After the assembly operations, the crane will travel to the required lift-off
positions. The length of the area required for assembly operations will depend mainly on
the boom length of the crane. The assembly area will be cordoned off and only Orascom
personnel will be allowed to work inside this restricted area.
4.2 Delivery of Superstructure
The Superstructure will be delivered to the site using by a lowbed trailer (Wooden mats
will be positioned underneath the outrigger to spread the load.
4.3 Crawlers assembly
Once the Superstructure has been delivered, the crawlers can be installed. This will be
done with an assist crane.
4.4 Installing Superstructure counterweight
Set the A frame towards the position of the gantry. Then place the Superstructure
counterweight support base plates and install counterweights on the ground as suitable
for the gantry on the rear of the Carbody to install to the superstructure. Crawl the
crane backwards to approximately 70mm close to the counterweights. Connect the
gantry guy lines to the counterweight hanger using suitable pins. Extend and retract the
cylinders as suitable for installing the counterweights. Operate the remote control to
lift the counterweights. Install the gantry fixing points.
10
4.5 ASSEMBLY OF MAIN BOOM
The main boom will now be assembled directly in front position of the basic
machine, by using assist crane, the boom sections will be assembled according to
rigging manual on the ground.
The CC-1800 will commence to raise the main boom until the boom head lifts clear.
The hook block will be positioned under the boom head. The main hoist wires will
then be reeved to the hook block. All limits will be connected (Einzieh readings;
overload warnings; anti- two blocking device; etc.).
11
5 Weather conditions
In general the operation shall not proceed unless a weather report forecasting suitable conditions
for a minimum of twenty-four hours or three times the operation period whichever is the
greatest, has been received. Prior to the start of the operation, the Client will be consulted
regarding the decision whether to proceed with the operation or to postpone it due to weather
conditions or other restrictions. A maximum wind criteria for starting the operation is
proposed to be Wind- force 5 (Beaufort) and decreasing.

Method of Statement of CC1800 Crane

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METHOD

Burullus 4800 MW Combined Cycle Power Plant Project

1.1 INTRODUCTION TO THIS MANUAL 2

2.1 SUMMARY OF WORK SCOPE 3

3.1 CONDITIONS FOR LIFTING 3

4 ERECTING PROCEDURE FOR CC-1800

4.1 SITE DATA 7

5 Procedures for Crane Disassembling 12

1.1 INTRODUCTION TO THIS MANUAL

1.2 WEIGHTS OF THE MAIN COMPONENTS

2.1 SUMMARY OF WORK SCOPE

3.2 CRANE CONFIGURATION

The CC-1800 will be erected in the following configuration:

DEMAG CC-1800 300t Crawler Crane (SSL)

Crawler Centers: 7.2 m

The assist cranes used are as follows:

RT- 9130 or Equivalent

3.5 Line of command

3.5.1 Organizational chart

The lifting supervisor is in charge of the actual lifting operation.

3.5.3 Crane Operator

3.6 Pre lift checks

Following things are checked prior to the lifting operation:

4.1 SITE DATA

4.2 Delivery of Superstructure

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