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Method Statement for Heavy

Girder Installation

Misr Co. for Mechanical & Electrical Projects “KAHROMIKA”

Suez Thermal Power Plant 1x650MW Project

DOCUMENT TITLE: Method Statement for Heavy


Girder Installation

Equipment No. : Heavy Girder


Client : ANSALDO CALDAIE.

0 24 May Method Statement


2014 for
Lifting Heavy Girder
KAH KAH ANSALDO
Rev. No. Issued Date Description Prepared by Reviewed by Approved
Eng. Ashraf Salama Eng. Ahmed Salama

Method statement and work page 1 of 7


Project: Suez Thermal Power Plant 1x650 MW
Method Statement for Heavy
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

 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
Appendix C
 Lifting Plan No 43 & 39

Appendix D
 Job Hazard Analysis

Method statement and work page 2 of 7


Project: Suez Thermal Power Plant 1x650 MW
Method Statement for Heavy
Girder Installation

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”

- Heavy girder Center of Gravity Calculation


- Lifting lug calculations
- Bevel Angle of Lifting lug calculations
- Scaffolding calculations of Heavy girders
- Life line calculations
5.2 Preparation for lifting "Installation Some temoprary itmes for lifting"

- Installation scaffolding on Heavy Girders


- Installing Temporary Lifting Lugs.
- Installing Life line

Method statement and work page 3 of 7


Project: Suez Thermal Power Plant 1x650 MW
Method Statement for Heavy
Girder Installation

5.3 Lifting the Heavy girders


 Set-up Crawler crane 500 tons in position.
 Lifting Heavy Girder from Assembly area to Boiler area by crawler crane 500 tons.
 Lifting Heavy Girder Beam by crawler crane 500 tons.
 Installation Heavy Girder in position.
 Alignment and bolt tightening Inspection.
 Remove scaffolding.

Method statement and work page 4 of 7


Project: Suez Thermal Power Plant 1x650 MW
Method Statement for Heavy
Girder Installation

6. Procedure

 Set up crawler crane 500 tons on position.

 Installation scaffolding on steel structure

Method statement and work page 5 of 7


Project: Suez Thermal Power Plant 1x650 MW
Method Statement for Heavy
Girder Installation

 Lifting Heavy Girder from Assembly area to Boiler area by crawler crane 500 tons.

 Lifting Heavy Girder Beam by crawler crane 500 tons

Method statement and work page 6 of 7


Project: Suez Thermal Power Plant 1x650 MW
Method Statement for Heavy
Girder Installation

 Installation Heavy Girder in position.

 Alignment and bolt tightening Inspection.


 Remove scaffolding.

7. Lifting Plan “ Appendix C”

Lifting Plan No. 43 & 39

8. Job Hazard Analysis “ Appendix D”

Method statement and work page 7 of 7


Project: Suez Thermal Power Plant 1x650 MW
Method Statement for Heavy
Girder Installation

Appendix A
 Drawing 30530-C-B3451 – Platform EL. 59.460 T.O.S. between Axes (B7 & B4)

Method statement and work


Project: Suez Thermal Power Plant 1x650 MW
Method Statement for Heavy
Girder Installation

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

Method statement and work


Project: Suez Thermal Power Plant 1x650 MW
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 of Heavy girders


* The critical scaffolding will be at the bigest span so our calculation will be for the bigest span 1 M "1000 mm"

The calculations will study four points, the points are


1- The load effect on the scaffolding pipes
2- The load effect on the wood sheet
3- The load effect on the scaffolding fittings " scaffolding connections together"
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= 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

1- The load effect on the scaffolding pipes


1-A
Maximum bending moment
NMB.M= WL/8
B.M=
22,950.00 KgCm
ALLOWABLE STRESSES -Steel

σy= 2.55 ton/cm2 (Steel)


σt= 0.58σy = 1.48ton/cm2 (In case of tension)
σb= 0.64σy = 1.63ton/cm2 (In case of bending)
σb= 1.632 ton/cm2 = 1,632.0 kg/cm2=

ALLOWABLE BENDING MOMENT & SAFE WORKING LOADS

σ=My/I
y=d/2= 2.415 CM
4
I=∏(d/2)⁴- ( (d-t)/2)⁴/4 Cm = 185.445 Cm4

So, M= 125,319.36 KgCm

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

ALLOWABLE STRESSES -Steel L = 50 Cm

σy= 2.55 ton/cm2 (Steel)


2
σt= 0.58σy = 1.48ton/cm (In case of tension)
2
σb= 0.64σy = 1.63ton/cm (In case of bending)
σb= 1.632 ton/cm2 = 1,632.0 kg/cm2=

ALLOWABLE BENDING MOMENT & SAFE WORKING LOADS

σ=My/I
y=d/2= 2.415 CM
I=∏(d/2)⁴- ( (d-t)/2)⁴/4 Cm4 = 185.445 Cm4

So, M= 125,319.36 KgCm

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

Wood Sheets ( Cross section 250mm *50mm)

2- The load effect on the wood sheet

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

2- The load effect on the wood sheet

Maximum bending moment


B.M= WL/8
KgCm
B.M= KgCm
22,950.00

ALLOWABLE STRESSES -Steel

σb=0.0438 x 104 kg/Cm2


σb= 438.0 kg/cm2=
0
ALLOWABLE BENDING MOMENT & SAFE WORKING LOADS

σ=My/I
y=t/2= 2.5 CM
I=d*t³/12 cm4 = 260.417 Cm4

So, M= 45,625.00 KgCm

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"

W= 1,836.00 Kg = 17,992.80 N = 17.9928 KN

The effect of load in the two connection points will be W/2 = 8.9964 KN

ALLOWABLE Weight according to the standard "AW"

You will found the W < AW

Drop Forged Double Coupler Description Weight (kg)

Bolt and nut: 1/2"*21mm


Standard: EN 74-1:2005 class B & BS1139
Surface Finish: electroplated
Slipping force: 1.05
Δ1 = 7 mm, Fs,5%=19.5KN;
1 ≤Δ2 ≤2 mm, Fs,5%=24.8KN
Distortion force: Ff,5%/Yr=75KN

Drop Forged Swivel Coupler Description Weight (kg)

Bolt and nut: 1/2"*21mm


Standard: EN 74-1:2005 class A & BS1139
Surface Finish: electroplated
Slipping force: 1.25
Δ1 = 7 mm, Fs,5%=11.5KN;
1 ≤Δ2 ≤2 mm, Fs,5%=18.8KN
Distortion force: Ff,5%/Yr=67KN 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

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"

W= 1,836.00 Kg = 17,992.80 N = 17.9928 KN

The effect of load in the two connection points will be W/2 = 8.9964 KN

ALLOWABLE Weight according to the standard "AW"

You will found the W < AW

Girder Coupler (Beam Clamp) Description Weight (kg)

Bolt and nut: 1/2"*21mm


Standard: AS/NZS1576.2 ( In EN74-1/ BS1139,
no related standard related beam clamp)
Surface Finish: electroplated 1.50
Strength test: P=30.0KN, Neither clamp showed any
permanet set.
Slip test: P=12.5KN, Slip≤6mm
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

Lifting Lugs Calculations


A1

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))

1- A3= V* T T 4- A4 = The welding area = N*(2W+2T)

τ= P/A= P/VT V T
V= P/Tτ
N
W
The welding shape K

τ= P/A & A= A1+A2= 2W*N+2T*N


A= 2N(W+T) 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

Ton N Inch mm Inch mm Inch mm Inch mm Inch mm Inch mm Inch mm Inch mm


1 1.00 9,800 5/8 16 5/9 14 1 3/8 35 1 1/9 28 4/5 20 1 7/9 45 3/8 9 3/8 10

2 1 1/2 14,700 3/4 19 5/9 14 1 2/3 42 1 1/6 30 4/5 20 2 51 4/9 11 3/8 10

3 2 19,600 7/8 22 5/6 21 2 49 1 1/4 31 4/5 20 2 1/5 56 1/2 14 3/8 10

4 3 3/4 36,750 1 25 5/6 21 2 1/2 63 1 3/8 35 7/8 22 2 3/7 61 1/2 14 3/8 10

5 4 3/4 46,550 1 1/8 29 5/6 21 3 77 1 1/2 39 1 24 3 77 1 24 3/8 10

6 6 1/2 63,700 1 1/4 32 1 1/9 28 3 1/3 84 1 2/3 42 1 26 3 1/3 84 1 26 1/2 13

7 8 1/2 83,300 1 3/8 35 1 1/9 28 3 6/7 98 2 49 1 1/4 31 3 6/7 98 1 1/4 31 1/2 13

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

12 25 245,000 2 1/4 57 1 1/9 28 7 3/7 189 3 77 2 48 6 3/4 171 2 3/5 66 3/4 19

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

14 50 490,000 3 76 2 1/5 56 8 4/5 224 5 126 3 4/9 88 9 1/3 237 3 74 1 25


15 75 735,000 3 1/2 89 2 1/5 56 12 1/9 307 5 2/9 133 3 1/2 88 11 2/7 286 4 2/7 109 1 25

The cross section area according to the above dimensions


Case No.

P A1 A2 A3 A4

Ton N Inch² mm² Inch mm Inch mm Inch mm


1 1.00 9,800 1/5 132 2/5 268 3/7 280 1 659

2 1 1/2 14,700 1/4 160 1/2 319 3/7 281 1 1/6 753

3 2 19,600 4/9 284 7/8 562 2/3 424 1 1/2 941

4 3 3/4 36,750 4/9 290 1 2/9 785 5/7 466 1 3/4 1,129

5 4 3/4 46,550 7/9 501 1 4/7 1,009 4/5 507 2 1,317

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

9 12 117,600 1 5/6 1,178 3 2/3 2,356 1 1/2 983 4 2/7 2,760

10 13.50 132,300 2 1,237 3 5/6 2,466 1 3/4 1,135 4 1/2 2,885

11 17 166,600 2 1,302 4 2,605 1 7/8 1,209 4 2/3 3,011

12 25 245,000 2 6/7 1,840 5 2/3 3,673 2 1,348 9 5,834

13 35 343,000 4 2/7 2,768 8 4/7 5,535 5 1/5 3,353 11 4/7 7,465

14 50 490,000 6 3/8 4,116 12 3/4 8,232 7 3/5 4,897 15 5/9 10,036


15 75 735,000 9 1/2 6,103 19 12,206 7 2/3 4,932 20 2/9 13,047

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

Heavy girder Life line calculations

DEFINITIONS AND GIVEN DATA


L= Span = The overall length of Life line ( Wire Robe) measured from one end-anchor to the other, L= 12,898 mm
ϵ = Strain will be on the rope (mm/mm) ϵ =δ /L
δ= Elongation of the rod (By mm) = δ= ϵ*L
β= Deflection =The vertical displacement between (By mm) =
Ɵ₁=Ɵ₂= By Degree , Deflection angle = The angular difference between the Life line ( Wire Robe) when at rest and when deflected under load
d=Wire Rope Diameter = 12 mm "6*37 with steel core"
A= cross section area of the rope = 113 mm²
P= The average weight of person = 150 Kg
K=The Number of persons will use the life line,K = 5
F=Impact Factor = 1.2
W=K*P*F =8*150 *9.8 m/s², The weights which were loaded to the life line,W= 8,820 N 8.82 KN
E= Modulus of elasticity of the rope construction = 6,000 Kg/mm2= 58,800.00 N/mm2
I= Constant moment of inertia = For circle cross section =∏12⁴/64 1,017 mm⁴

500 mm 12,898 mm 12,898 mm 500 mm

26,796 mm

L Angle 20 Cm*20Cm *20mm L/2 L/2


Ɵ₂ Ɵ₁
β
20 Cm

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

Tensile strength = 400 : 550 N/ mm² Ɵ₁ Ɵ2

σ=W/A = 78.03 N/ mm² =σ=Eϵ


β
ϵ= σ/E 0.001326964 δ= ϵ*L 17.11518 mm

δ= 17.11518 mm

β²= S²-(L/2)² S=(L/2)+(δ)


Where the δ is small , we Assume that the Elongation of the rod "δ" will be in L/2 β²= 221,044.53 S= 6,466.12
β= 470.15 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

W=T₁ *Sin Ɵ₁+T₂*Sin Ɵ2 Ɵ2 Ɵ₁


T₁=T₂ & Ɵ₁= Ɵ2
W=2*T₁ *Sin Ɵ₁ T₁= W/2Sin Ɵ₁
2Sin Ɵ₁ 0.145420771
W=K*P*F
T₁= 60,651.58 N

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

The welding area = L*N


L Angle

L Angle N

The welding shape K

τ= P/A & A= L*N


The welding area = L*N *2
Welding Area " Red Area"

L Angle
Fillet Weld Welding Area

L Angle N

The welding shape K

τ= P/A & A= L*N


K

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

P= 150,000 N & W= 8,820 N

P= 150,000 N >> W= 8,820 N Ok

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

760 6,149 740 1000 9,397 900 640 5,108 850

G245015.1 G245026.1 G245014.1

7,649 11,297 6,598


25,544 mm
mm mm mm

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 ∑

7,649 11,297 6,598 25,544 mm

22,139 29,462 18,299 69,900 Kg


Kg Kg Kg

W*X= W 15.1 * X 15.1 + W 26.1 * X 26.1 + W 14.1 * X 14.1


(69,900 Kg) *X = (22,139 Kg) *( 3,834.5 mm ) + (29,462 Kg) *( 13,347.5 mm ) + (18,299 Kg) *( 22,140 mm )
X= { (22,139 Kg) *( 3,834.5 mm ) + (29,462 Kg) *( 13,347.5 mm ) + (18,299 Kg) *( 22,140 mm )} /69,900 Kg
X= 12,636 mm "The distance bteween the Center of Gravity of total haevy girder and the Y axis"
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

Bevel Angle of Lifting lug calculations


A1

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

4- A4 = The welding area = N*(2W+2T)

T
N
W
The welding shape "Fillet Weld" K

K τ= P/A & A= A1+A2= 2W*N+2T*N


K K K K A= 2N(W+T) 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

Ton N Inch mm Inch mm Inch mm Inch mm Inch mm Inch mm Inch mm Inch mm


14 50 490,000 3 76 2 1/5 56 8 4/5 224 5 126 3 4/9 88 9 1/3 237 3 74 1 25

At Bevel Angle 45 and K =25 mm


τS = shear stress will be on the welding area The welding shape "Fillet Weld"
τS = P/2N(W+T) N= K * Cos 45 Cos 45= 0.707
τS = P/( 2K * Cos 45*(W+T))
τS = 48.822607 N/mm²
τ = Allowable shear stress = 0.35 x Yield stress.
Yield stress. =250 N/mm²
τ = Allowable shear stress = 87.5 N/mm²

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

Method statement and work


Project: Suez Thermal Power Plant 1x650 MW
Misr Co. for Mechanical & Electrical Projects KAHROMIKA
Suez Thermal Power Plant 1x650 MW
Site Technical Office Dept.

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

Check List: YES No N/A


Energized power lines within Boom Radius?
Ground condition/bearing capacity Considered?
Night Shift/Visibilty Considered? 
Fire/explosion hazards within Boom radius?
Suitable Communication means available ?
Weather/Wind Conditions safe?
Wind speed less than 23 Mile Per Hour(20 knote, 10m/s)
Suitable Barricade set/people kept away?

PERSONNEL INVOLVED Name Signature Date


Lifting Plan Originator: Eng. Ashraf Salamah
KH Construction Manager: Eng. Karim Gamal
KH Superattendant: Eng. Mahmoud Saed
Competent Rigger : Saed Abdel Khalek
Crane Operator :
KH Safety Manager: Ahmed Elhadidy
ANSALDO Technical Office : Mr. Crevatin Furio
ANSALDO HSE Manager : Eng. Yasser Abdel Razek
PGESCO Mech Approval :
PGESCO HSE Approval :
Misr Co. for Mechanical & Electrical Projects KAHROMIKA
Suez Thermal Power Plant 1x650 MW
Site Technical Office Dept.

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

Check List: YES No N/A


Energized power lines within Boom Radius?
Ground condition/bearing capacity Considered?
Night Shift/Visibilty Considered? 
Fire/explosion hazards within Boom radius?
Suitable Communication means available ?
Weather/Wind Conditions safe?
Wind speed less than 23 Mile Per Hour(20 knote, 10m/s)
Suitable Barricade set/people kept away?

PERSONNEL INVOLVED Name Signature Date


Lifting Plan Originator: Eng. Ashraf Salamah
KH Construction Manager: Eng. Karim Gamal
KH Superattendant: Eng. Mahmoud Saed
Competent Rigger : Saed Abdel Khalek
Crane Operator :
KH Safety Manager: Ahmed Elhadidy
ANSALDO Technical Office : Mr. Crevatin Furio
ANSALDO HSE Manager : Eng. Yasser Abdel Razek
PGESCO Mech Approval :
PGESCO HSE Approval :
Method Statement for Heavy
Girder Installation

Appendix D
 Job Hazard Analysis

Method statement and work


Project: Suez Thermal Power Plant 1x650 MW
‫نموذج تحليل المخاطر‬ ‫الموقع ‪ -:‬محطة توليد كهرباء السويس الحرارية عقد ‪501‬‬
‫شركة كهروميكا‬
‫)‪Job Hazard Analysis (J H A‬‬ ‫التاريخ ‪2014 / 1 / 51 -:‬‬
‫"إدارة السالمة"‬

‫‪Heavy Guarder‬‬ ‫النشاط ‪ -:‬رفع وتركيب‬

‫طرق التحكم‬ ‫المخاطر الكامنة‬ ‫خطوات العملية‬ ‫م‬


‫‪ 5/5‬تدريب العاملين المشاركين بهذة العملية (‪.(Working at Height( & )Start Card‬‬
‫‪ 2/5‬ارتداء مهمات الوقاية المناسبة ( خوذة ‪ +‬نظارة ‪ +‬حذاء امان ‪ +‬حزام امان )‬
‫‪ 3/5‬ضرورة وجود ( ‪ ) for arrestor‬او وير خامس بالونش الستخدامه في عملية الربط اثناء العمل ‪.‬‬ ‫‪ 5/5‬السقوط من اعلى ‪.‬‬
‫‪1‬‬
‫‪ 4/5‬التأكد من المان باسكت تمت معايرته وسليم ‪.‬‬ ‫‪ 2/5‬سقوط ادوات واشياء من اعلى‪.‬‬ ‫العمل على ارتفاعات باستخدام‬
‫‪ 1/5‬التأكد وجود العدد الالزم بالمان باسكت‪.‬‬ ‫‪ 3/5‬سقوط المان باسكت‪.‬‬ ‫‪ man basket‬و السقاالت‬
‫‪ 6/5‬التاكد من وجود اشراف المسئول ( الفني ‪ +‬المهندس )‪.‬‬ ‫‪ 4/5‬سقوط من السقالة‬
‫‪ 1/5‬التاكد من الويرات المستخدمة سليمة وتمت معايرتها وعليها الكود اللوني‬
‫‪ 8/5‬السقالة التي يتم العمل عليها تكون مكتملة ومثبتة جيدا‬
‫‪ 5/5‬تدريب العاملين على ‪Starrt card‬‬
‫‪ 2/5‬التاكد من المبات المثبتة بالطرد‬
‫‪ 3/5‬التاكد من اللحامات التي تمت على المبة بواسطة مهندس جودة‪.‬‬
‫‪ 4/5‬فحص الويرات وعدة الرفع والتاكد من معايرة الويرات‬
‫‪ 1/5‬اتاكد من وجود الكود اللوني على عدة الرفع‪.‬‬
‫‪ 6/5‬التاكد من ان عدة الرفع المستخدمة مطابقة لخطة الرفع‪.‬‬
‫سقوط الطرد‬ ‫‪)5‬‬
‫‪ 1/5‬التاكد من صالحية الونش وتمت معايرته‪.‬‬
‫قطع الويرات‬ ‫‪)2‬‬
‫‪ 8/5‬التاكد من ان الونش مطابق لخطة الرفع‪.‬‬ ‫نقل ‪ Heavy‬بواسطة الونش ‪300‬‬ ‫‪2‬‬
‫سقوط الونش‬ ‫‪)3‬‬
‫‪ 9/5‬التاكد من المسافة بين الونش والطرد مطابقة لجدول االحمال وخطة الرفع‬
‫سقوط اجزاء السقالة المركبة على الطرد‬ ‫‪)4‬‬
‫‪ 50/5‬التاكد من شهادة الوناش وانه مدرب جيدا‬
‫‪ 55/5‬التاكد من كفاءة القائمين على عملية الرفع وانهم مدربين جيدا‪.‬‬
‫‪ 52/5‬التاكد من القائم على تشغيل الوناش شخص واحد ومدرب جيدا‪.‬‬
‫‪ 53/5‬التاكد من ربط الطرد باحبال الحواش‪.‬‬
‫‪ 54/5‬وجود الشخص الضروري فقط اثناء الرفع‬
‫‪ 51/5‬وضع شريط تحذير وحواجز حول منطقة الرفع‬
‫‪ )1‬تدريب العاملين على ‪Starrt card‬‬
‫سقوط الطرد‬ ‫‪)5‬‬
‫‪ )6‬التاكد من المبات المثبتة بالطرد‬
‫قطع الويرات‬ ‫‪)2‬‬ ‫رفع ‪ Heavy‬بواسطة الونش‬
‫‪ )1‬التاكد من اللحامات التي تمت على المبة بواسطة مهندس جودة‪.‬‬ ‫‪3‬‬
‫سقوط الونش‬ ‫‪)3‬‬ ‫‪ 100‬طن‬
‫‪ )8‬فحص الويرات وعدة الرفع والتاكد من معايرة الويرات‬
‫سقوط اجزاء السقالة المركبة على الطرد‬ ‫‪)4‬‬
‫‪ )9‬اتاكد من وجود الكود اللوني على عدة الرفع‪.‬‬

‫مدير السالمة والصحة المهنية‬ ‫المراجعة‬ ‫مسئول القسم‬ ‫اعداد‬


‫االسم ‪:‬‬ ‫االسم ‪:‬‬ ‫االسم ‪:‬‬ ‫االسم‪:‬‬
‫التوقيع ‪:‬‬ ‫التوقيع ‪:‬‬ ‫التوقيع ‪:‬‬ ‫التوقيع ‪:‬‬
‫‪Page 1 of 2‬‬
‫نموذج تحليل المخاطر‬ ‫الموقع ‪ -:‬محطة توليد كهرباء السويس الحرارية عقد ‪501‬‬
‫شركة كهروميكا‬
‫)‪Job Hazard Analysis (J H A‬‬ ‫التاريخ ‪2014 / 1 / 51 -:‬‬
‫"إدارة السالمة"‬

‫‪Heavy Guarder‬‬ ‫النشاط ‪ -:‬رفع وتركيب‬

‫‪ )50‬التاكد من ان عدة الرفع المستخدمة مطابقة لخطة الرفع‪.‬‬


‫‪ )55‬التاكد من صالحية الونش وتمت معايرته‪.‬‬
‫‪ )52‬التاكد من ان الونش مطابق لخطة الرفع‪.‬‬
‫‪ )53‬التاكد من المسافة بين الونش والطرد مطابقة لجدول االحمال وخطة الرفع‬
‫‪ )54‬التاكد من شهادة الوناش وانه مدرب جيدا‬
‫‪ )51‬التاكد من كفاءة القائمين على عملية الرفع وانهم مدربين جيدا‪.‬‬
‫‪ )56‬التاكد من القائم على تشغيل الوناش شخص واحد ومدرب جيدا‪.‬‬
‫‪ )51‬التاكد من ربط الطرد باحبال الحواش‪.‬‬
‫‪ )58‬وجود الشخص الضروري فقط اثناء الرفع‬
‫‪ )59‬وضع شريط تحذير وحواجز حول منطقة الرفع‬

‫مدير السالمة والصحة المهنية‬ ‫المراجعة‬ ‫مسئول القسم‬ ‫اعداد‬


‫االسم ‪:‬‬ ‫االسم ‪:‬‬ ‫االسم ‪:‬‬ ‫االسم‪:‬‬
‫التوقيع ‪:‬‬ ‫التوقيع ‪:‬‬ ‫التوقيع ‪:‬‬ ‫التوقيع ‪:‬‬
‫‪Page 2 of 2‬‬

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