BILFAL HEAVY INDUSTRIES LTD.

P.O. BOX 30025

YANBU INDUSTRIAL CITY – 31961
KINGDOM OF SAUDI ARABIA
Email: Tec@bilfal.com
Website: www.bilfal.com

SWCC - YANBU 20 MIGD

MSF EVAPORATOR

Client: DOOSAN HEAVY INDUSTRIES &

CONSTRUCTION Co. Ltd.

METHOD STATEMENT FOR OVERTURING OF ROOF BUNDLE

0 17-06-2014 JACOB T. SANTOSH ISSUED FOR CONSTRUCTION

Rev. Date Prepared Approved Description

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INDEX

PURPOSE

RESPONSIBILITIES

MATERIAL LIST

SAFETY

TECHNICAL INFORMATION

PRE-LIFT CHECK LIST

BUNDLE LIFTING

PREPARATION

Preparation – 1: Outfitting of 90 Ton Spreader Beam

Preparation – 2: Outfitting of 40 Ton Spreader Beam

Preparation – 3: Positioning of Cranes and Bundle

BUNDLE FIRST LIFT

BUNDLE OVERTURN

A Bundle Horizontal Rotation 180°

B Bundle Vertical Turning 90°

Erection of BUNDLE
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PURPOSE
This method statement is intended to outline the activities for lifting overturning and
erection of Tube BUNDLE with roof panel in to Evaporator bottom sections. The major
works includes but not limited to Hiring / procurement of lifting equipments and tools,
Equipment location arrangements for Lifting and Erection of BUNDLE

RESPONSIBILITIES
Production/Site Manager:
Production / Site Manager is fully on behalf of Project Manager to manage all the
activities happen on site, directly report to the Project Manager with Responsible for
ensuring that all works are performed in accordance with this procedure

Project Engineer:
Responsible for the overall planning, coordination and control of the job

Production Engineer:
Responsible for field erection work implementation and maintaining acceptable quality
standard.

Field Superintendent and supervisor:

Responsible for the actual performance of the erection crew and actual checking of
the work progress to make that it is drawing specification and standard.

Safety Engineer:
Responsible for ensuring that all activities are carried out in a safety manner and
compliance with the established safety procedure

Quality Control Engineer:

Responsible to monitor and inspect the Bundle erection ensuring it is being done in
compliance with this procedure, ITP (Inspection and Test Plant), Drawing , Project
specification and other reference standard document and procedure.

MATERIALS LIST
1 Main Lift Crane: Crawler Crane 350 MT Capacity 1
2 Tailing Crane: Crawler Crane 110 MT Capacity 1
3 Service Crane-1: Mobile Crane 100 MT Capacity 1
4 Service Crane-2: Mobile Crane 50 MT Capacity 1
5 Spreader Beam Capacity 90 Metric Ton 18 Meter Length 1
6 Spreader Beam Capacity 40 Metric Ton 20 Meter Length 1
7 70 mm Dia Wire Rope Length 12000mm 4
8 35 Ton Capacity Wire Rope Length 12000mm 4
9 33 Ton Capacity Wire Rope Length 3000mm 8
10 70 mm Dia Wire Rope Length 6000mm 2
11 Shackles 55 Ton Capacity 6
12 Shackles 35 Ton Capacity 24
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SAFETY
1. Rigging must be made on Day Time and the wind must be below 30KmPh
2. Bearing Surface of Pins of Shackles and Lug Eyes of Slings Etc that turn during
erection are to be greased before making lift
3. One authorized person only will give instruction to the operators and Lifting
Crew.
4. The workers working on job site must be equipped with minimum PPE

TECHNICAL INFORMATION
Item No : Evaporator Roof Bundle (13 Nos.)
Size (L x B x H)
: 24400 x 11700 x 4500
Maximum
Weight of Largest
: 76000 Kgs. (Maximum Weight)
Bundle

MAIN LIFT CRANE

CRANE
Boom Length
Working Radius
Lifting Capacity
Extra Counter Weight
Weight of Lifting Gears
Weight of Crane Hook
Total Rigging Weight
% Of Chart Capacity
: 350 Metric Ton LIEBHERR Crane, with Extra 120
Ton Counter weight for super lift configuration
: 47000mm
: 9000 mm to 22000mm
: 120400 Kgs. at 22000mm WR
: 120000 Kgs.
: 13500 Kgs (Spreader Beam, Slings, Shackles Etc)
: ~2500 Kgs (120 Ton Cap. Hook)
: 92000 Kgs
: 76%

TAILING CRANE
CRANE : 110 Metric Ton KOBELCO Crane
Boom Length : 24400mm
Working Radius : 5000mm
Lifting Capacity : 77000 Kgs at 5000mm WR & Boom Lg 24400mm)
Counter Weight : 34500 Kgs
Weight of Lifting Gears : 8000 Kgs (Spreader Beam, Slings, Shackles Etc)
Weight of Crane Hook : ~1700 Kgs (120 Ton Cap. Hook)
Total Rigging Weight : 92000 Kgs

SERVICE CRANES
CRANE- 1 : 100 Metric Ton MOBILE Crane
CRANE- 2 : 50 Metric Ton MOBILE Crane
Total Rigging Weight : 92000 Kgs
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PRE-LIFT CHECK LIST

Checking of Shackles and Slings
Check the crawler path which is suitably reinforced
Checking of crane Ground compaction and protection for the Rail foundation
Checking of Crane, SPMT location marks
Assembly of all lifting Gears
Confirm Crane operator and Riggers are well aware about the lifting
sequences.
Confirmation of all Lifting Equipments, Lifting tools, slings, shackles are in
accordance with this procedure
Check lifting Orientation of Bundle, crane position with capacity of applied
crane base on crane specification issued by the crane manufacturer.

BUNDLE LIFTING
Preparation-1: 90 Ton Spreader Beam and Slinging Arrangement
Positioning of 350 Ton Capacity Lifting Crawler Crane, outfitted with 90 Ton
Spreader Beam, slings, shackles etc. as per below Sketch

90 Ton spreader Beam and Slinging Arrangement for

350n Main Lift Crane
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Preparation-2: 40T Spreader Beam and Slinging Arrangement

Positioning of 110 Ton Capacity Tailing Crawler Crane outfitted with 40 Ton
Spreader Beam, slings, shackles etc. as per below Layout

40 Ton spreader Beam and Slinging Arrangement for

110 Lifting Crane
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Preparation-3: Positioning of Cranes & Connection to Bundle

PLAN View for positioning of Cranes and Overall

Movement for BUNDLE Erection

Transport the bundle by 650 Ton SPMT, to designated erection area and
positioned as indicated in above sketch. Connect securely all slings from both
cranes to the BUNDLE lifting pad eyes as indicated in the above sketches.
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Bundle First Lift

After completion of attaching all slings to the BUNDLE, raise both crane hooks
until all slings become tighten for taking load. Then, check all slings and
connections. If any slings found loose or imbalanced shackles connections, it
must be rectified before start lifting.

Sequence
Lift the BUNDLE slightly by main Lifting Crane and Tailing Crane including 2
service cranes, Simultaneously in order to release SPMT

After releasing the SPMT, Slowly raise the BUNDLE in tandem, until it is in
the position indicated in the Sketch-1

Main Crane (350MT) slowly raise the BUNDLE upwards, while the tail crane
and 2 service cranes slowly release the hooks, until the bundle reach in
vertical position as indicated in the sketch-1

Once the BUNDLE in vertically balanced position, completely suspended on

Main Lift Crane, disconnect tailing Crane and service Cranes from the
BUNDLE as shown below sketches.

ELEVATION showing the First Lift of BUNDLE with Main Lift Crane & Tailing
Cranes
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ELEVATION showing the BUNDLE completely transferred to Main lifts Crane

and releasing Tailing Crane

BUNDLE OVERTURN

A. Bundle Horizontal Rotation- 180°

After detaching of all tailing Crane and Service Cranes, the Main Lift Crane,
slowly slew clockwise ~55°, until the BUNDLE can comfortably rotate
horizontally 180°, within the working radius up to 22 meter.

Sequence
Boom Swing ~55° as indicated below Sketch

Rotate carefully the BUNDLE 180° clockwise manually.

Adjust the Boom while rotating the Bundle in order to maintain the safe
working radius.
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PLAN and ELEVATION showing the 180° Rotation

Using with Main Lift Crane
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B. Bundle Vertical Turning (90°)

After completion of 180° BUNDLE rotation, the Main Lift Crane slowly slew
anticlockwise until the BUNDLE reach up lifting location.

Once the bundle reach in lifting position, connect Tailing Crane with 4 Nos
33Ton X 3000mm Long wire rope (Remove existing 12000mm long rope) and 2
Service Cranes for 90° Vertical Turn as shown below sketch.

PLAN and ELEVATION showing the 180° Rotation

MH-7560-00-02 Rev. 0 Page 12 of 14

Using with Main Lift Crane

Sequence
Connect the Tailing Crane at center and 2 service cranes either sides

Lift the BUNDLE up 12500mm High by Main Lift Crane,

Hold the BUNDLE by Tailing and service crane at 12500mm High.

Min Lift crane Boom up and hook down slowly until in order to reach the
bundle in horizontal position as shown below sketch

ELEVATION showing the Vertical Rotation Using with

Main Lift Crane Tailing Crane and 2 Service Crane
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BUNDLE ERECTION
After the BUNDLE reach in horizontal position at 12500mm level, release 2
service cranes in order to march both Main Lift Crawler Crane and Tailing
Crawler cranes with BUNDLE as shown below layout
MH-7560-00-02 Rev. 0 Page 14 of 14

Sequence
Slowly move both Main Lift crawler crane and Tailing Crawler Crane
simultaneously, towards the bottom section location.

Move the Bundle up to directly above position on the top of the Bottom
Section Assembly

Check all alignment and mach markings

Once the alignments and match markings are accepted, slowly erect the
Roof Bundle in to the Bottom Section

Once the Bundle is securely supported on the Bottom assembly, by means

of tack weld and temporary supports, then the cranes can be removed

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