ALE Newsletter February 2015

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IN THIS ISSUEALE News

ALE PeopleProject Focus

Branch FocusALE Technology

HSQECase Studies

new heightsTHE ALE NEWSLETTER • ISSUE 08

Welcome...Welcome to the February edition of the ALE newsletter, refreshed in a new format to keep you informed of our latest activities around the world.

“At ALE we recognise the importance of our people - the team that bind us together across the globe who deliver our values of Smarter, Safer and Stronger. It is the people within the company, supported by cutting edge equipment, that enables us to take a step above the competition as true market innovators delivering value for our customers in terms of safety, efficiency and cost effectiveness.

ALE perpetuates a culture of pushing boundaries by identifying customer needs, seeing opportunities in the market and delivering customer value. I’m really proud of the progress we have made in our equipment. Innovation is at the core of all our projects regardless of shape or size. But, it is only when the team works together that we do become Smarter, Safer and Stronger.”

Mark Harries

Global Managing Director

ALE ACHIEVE INTERNATIONAL SAFETY CERTIFICATION ALE UNVEILS ITS FIRST TROJAN TRUCK

ALE BREAKS RECORD WITH 42,780T JACK UP AND 47,830T LOAD-OUT

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WORLDWIDE HEAVY TRANSPORTATION AND LIFTING

Company News

ECR ACQUISITION SUCCESS We are pleased to announce that the acquisition of the ECR group in Australia is proving successful.

After the success of the joint venture, ‘ALE ECR Heavylift’, ALE acquired majority shares of ECR Group and amalgamated the joint venture partners under the ALE name in Australia.

Benefits that our customers have gained include the strength and knowledge of a global organisation with regional experience, investment in the equipment and services we can provide in this region and a combination of skills from both businesses for an end-to-end solution via a single interface.

We are committed to further investing in equipment to ensure that our current capabilities are continually available as well as new equipment purchasing as required to meet our customer’s needs.

ALE now operates from branches in Brisbane, Gladstone, Perth, Darwin and Port Hedland. We are looking forward to working on projects under the ALE brand in this region and will continue to update you on projects for Australia over the coming months.

ALE OPENS NEW OFFICE AND DEPOT FACILITY IN CASPIAN REGION

ALE LAUNCH JOINT VENTURE IN ANGOLA

ALE has signed a joint venture with UNICARGAS, a leading provider in the transportation and handling of light loads in Angola.

In over twenty years UNICARGAS has played a key role in the economic revitalization of this region with its continuous development of new solutions in the transport market. UNICARGAS are currently responsible for the multiservice terminal at Luanda’s Harbour and own five logistic centres located across the provinces of Benguela, Cabinda, Cunene, Malanje and Luanda.

The expansion policy of UNICARGAS, teamed with ALE’s interest in contributing to the industrial development of Angola, led to the joint venture UNICARGAS ALE. Together ALE and UNICARGAS can provide complimentary facilities and provide clients with a complete solution to their transportation and handling requirements.

ALE WIN 2014 ESTA AWARDIn 2014 we were delighted to receive a prestigious ESTA award for our successful installation of two 2,700t bridge arches across a river in Torun, Poland. A project which represented a major investment in the region.

Presented at a prestigious ceremony in Amsterdam, the ESTA awards are designed to recognise and drive standards in our industry. Our Torun Bridge project won the combined techniques category and involved the skidding, assembly and float installation of the arches over a 500m width of river in order to create a vehicle bridge.

GUINNESS WORLD RECORD – UAE Many congratulations to our UAE region who have been awarded a Guinness World Record for the successful transportation of a 13,191.98t PUQ deck in Jebel Ali - the ‘Heaviest Load Moved by SPMTs’.

The award was presented to Lamprell by the UAE Guinness World Records

adjudicator Samer Khallouf at a celebratory event held in Dubai.

ALE utilised five hundred and twelve axles of SPMT to complete the transportation and load-out of the PUQ deck which measured 98.5m long, 46m wide and 58.8m high. The deck was transported 883m, taking 4 hours for transport and 10 hours for load-out to complete.

Office News

ALE’S SPANISH BRANCH HOSTS SUCCESSFUL TECHNICAL CONFERENCE ALE’s Spanish branch held a technical conference, focusing on the civil work sector. As the fourth in a series of highly acclaimed events organized by ALE, the conference was geared towards young professionals from the civil engineering industry and the main aim was to present the work methods used by ALE in the sectors in which we operate.

The event was attended by professionals from the most prestigious companies in Spain. The special guest speaker was Mr. Juan Luis Bellod, the General Manager of Cesma Company, who gave a talk based on his experience as a Project Design Engineer, with specific reference to bridge engineering and construction.

ALE MOVES US BASEALE has moved its US operation into new purpose-built premises in Houston, the city which has been its base for the past two years.

With this move comes a new business strategy to build an individual identity for ALE across the US and expand ALE’s own portfolio of business particularly in the oil and offshore sectors.

“The time is right for us to make a name for ourselves with those who can influence the growth of our US business and help us expand our network,” says Vice President Rodney Rather. “This move to new, ALE-dedicated offices in Houston demonstrates the significant service offering that we can now offer to our clients in the US.”

ALE OPENS SECOND BRANCH IN IRAQWith a presence of almost 25 years in the Middle East, we are pleased to announce a new ALE branch in Iraq. Located in Erbil, the capital of the Kurdistan region of Iraq, the branch is the second to be situated in Iraq after the Basra office which was launched in 2012. This branch is ideally located to support our clients in this growing market.

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ALE’S SPANISH OFFICE CELEBRATE WITH LONG

SERVICE AWARDS The whole team in our Spanish branch came

together to congratulate their 11 colleagues on a total of 201 years of service across a

variety of roles including Depot Manager, Logistics Co-ordinator, Financial Controller, Supervisor and

General Manager.

Following our expansion into the Caspian region last year, ALE has opened an office in Atyrau, Kazakhstan. This is ALE’s second office in the region, after the office in Baku which opened in 2013. ALE’s Regional Operations Manager Ali Yoldashov, who is managing the new Atyrau office, said: “We are delighted to see a new branch open in Atyrau. ALE’s strong, steady growth and expanding global footprint are real consequences of our fast expansion in the area. By opening a new office in Atyrau, we can build on our strong Central Asian client base, whilst being strategically placed to support the operational needs of the region. With dedicated teams using specific local knowledge, combined with owning one of the biggest cranes in the area, we are planning to provide better quality solutions to our customers.”

ALE have also purchased a new yard facility in Baku, Azerbaijan. This is the main base for operations across this region made up with countries – Azerbaijan, Kazakhstan, Turkmenistan, Uzbekistan, Tajikistan, Kyrgyzstan and Georgia. Fuad Mammadov, Caspian Regional Business Development Manager said: “Today’s oil and gas, power and energy, and construction industries require professional sub-contracting on each and every phase of project implementation. Our aim is to work with our clients to provide a solutions centre for any difficult and complicated tasks using the technology and innovation available to us as part of the ALE group. It is this and the ability to deliver that will make us successful in this highly competitive market.”

WORLDWIDE HEAVY TRANSPORTATION AND LIFTING

ALE ANNOUNCES LATEST INNOVATION – THE MEGA JACK 800 The Mega Jack 800 is the latest product launched in our ground-breaking Innovation Series. It has been designed to provide a unique jacking solution which bridges the gap in the capacities of current solutions, and is able to integrate with other heavylift equipment for a more efficient solution.

The Mega Jack 800 is based on similar principles to those of our record breaking Mega Jack and will provide jacking solutions for a wide range of industry sectors including civil, mining, power generation and offshore.

The Mega Jack 800 is made up of jacking towers, each with a capacity of 800t, and is totally scalable to accommodate a wide variety of individual projects. It is containerised, can be built completely at ground level and utilises a low assembly height for installation.

The Mega Jack 800’s computer-based system controls the automated programming and operation of the cassette feed-in system. For minimal on-site disruption this feed-in system requires only one point of feed which can be on any side to adapt to restricted space.

The jacking cassettes plus starter beam and end cassette can be bolted together to take up to a massive 25% uplift per corner.

Harrie Smetsers, Research and Development Manager at ALE comments: “We conceived the idea of the Mega Jack 800 through careful analysis of the current market, and identifying areas for improvement in efficiency. We believe we have created a system which integrates successfully with current solutions by bridging the gap in capacity, and enhancing the capability we can offer.”

NEW ‘WIDENING TRAILERS’ OPEN UP AUSTRALIAN MARKET FOR ALE

ALE is now able to increase the scale of its services in Australia thanks to a new fleet of trailers which can react with extreme flexibility to the country’s road regulations.

The ALE trailers feature Goldhofer’s newly developed hydraulic width adjustment system which enables the spread of axle load required to adhere to the different weight/width restrictions for road transport throughout Australia.

ALE has already taken delivery of forty axle lines fitted with this innovative system, and a range of accessories including goosenecks and ramps.

The specifications of the new modules are a wheelbase of 1,800mm, with adjustable widths of 3,480mm, 3,700mm, 4,000mm, 4,500mm and 4,900mm. As a result, the various vehicle combinations can be used at maximum axle load on the public roads of all six Australian states.

Specifically designed hydraulic beams fixed to the middle and to each end of the trailer deliver the width change. This can be

achieved by just two operatives in approximately one hour and without the use of a crane or lifting equipment.

The design of the new trailer makes it compatible with the company’s trailer fleet equipment and accessories.

David Purslow, General Manager - Global Operations, said: “This reduces costs and future-proofs the equipment, both important considerations when investing in, and developing our optimum transport solutions.”

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Equipment NewsALE DEPLOYS TWO LR11350 CRANES WITH P BOOMWe have recently deployed two LR11350 cranes, one of the largest type of crawler cranes in our fleet, for several jobs in Australia and Argentina.

In Australia, the 1,350t capacity crane was utilised to install a CO2 absorber column weighing 605t in Darwin. More recently, the crane completed another job in Cape Lambert, Western Australia, where two 400t car dumper cells were installed.

From May until October, another LR11350 crane fitted with P Boom was used to lift three coke drums, weighing 435t and measuring 42m each, as part of YPF’s Nuevo Coke A project in Buenos Aires, Argentina.

ALE’s Project Manager Hernán Asensio, said: “In this project we faced several challenges; working to install such large, heavy coke drums in a small working area filled with obstacles such as trees and buildings. By using the LR11350 crane with P boom and four configurations, we were able to optimise the maneuvers in the small space we had available and minimise the removal of any obstacles. The client was pleased we could provide the engineering solution within the challenging environment.”

ALE UNVEILS ITS FIRST TROJAN TRUCKHeralded as the first in the next generation of vehicles in the heavylift industry, the new Trojan truck signals a major breakthrough in capability, fuel efficiency and reliability.

Designed by ALE engineers and produced in the UK, the Trojan’s unique feature is its ability to link up multiple tractor units in a command and drone convoy.

A key design consideration for ALE was to

ensure that the power could be delivered effectively, producing significantly improved tractive effort compared to other standard market products. Critical to this was to ensure that the trucks provided a significant and balanced footprint which would also assist with retardation.

“We wanted to replace our current fleet of trucks with a specification that improved

on vehicle performance, capability and fuel efficiency but there was no other truck on the market that delivered this,” said Gary Butler, ALE Project Manager and designer of the Trojan truck.

This is the first of a fleet of six new trucks to be built by ALE. Four will be retained in the UK, with two destined for the United Arab Emirates.

WORLDWIDE HEAVY TRANSPORTATION AND LIFTING

WWW.ALE-HEAVYLIFT.COM

Q: How long have you worked for ALE?

A: I have worked for ALE since September 2011. I have found that the company provides a highly satisfying working environment, where the combination of putting into practice my previous experience and learning new innovative concepts is incredibly rewarding and enjoyable.

Q: What is it like working in Iraq?

A: It is quite difficult to describe the working environment in Iraq; the unique conditions require flexibility, forward planning and understanding. However, with a good support system provided by selected colleagues and local content, challenges are easily overcome.

Q: What is the focus within the region?

A: The focus within the Mesopotamian region is growth; this growth is already seen in the investments made in facilities and equipment as well as recruitment of new staff. I’m looking to explore and expand into neighbouring countries which will be soon become the protagonist of remarkable oil and gas development and a corridor between the Middle East and the Caspian region.

Q: What responsibilities does your role cover?

A: My role covers multiple responsibilities. As Regional Manager I had to establish the branch in Iraq and have been through each and every aspect of opening a company, making it successful and ensuring that it remains successful. The initial opening of the branch included researching the area and security considerations, selecting subcontractors, establishing key relationships, liaising with local authorities, recruitment, overseeing construction, commercial activities inside and outside the country, finance and operations.

Q: How has the team/branch/region/company changed while you have worked here?

A: When I arrived in Iraq I had to develop the business from the beginning. Gradually, with a clear vision combined with rewarding local team work and constant efforts, we have grown and established an office, an operational base life support camp, storage areas within the Free Zone of Khor Al Zubair and a recently a new opening in Erbil. We have invested in a fleet of new equipment. We have a team of 80 personnel and we are continually growing.

Q: What do you enjoy most about working for ALE?

A: For me there are two key things that make me proud to work for ALE; the innovative thinking and the continuous worldwide growth of the company. ALE invests in its people and in research and development. This allows the teams to think outside the box to create equipment that completes projects more efficiently, or takes on projects that would not previously have been possible. In terms of growth, I enjoy the opportunity and the privilege to be a ‘frontiersman’ to lead ALE towards new challenging but highly remunerative markets. All these highlight the values of being ‘Smarter, Safer, and Stronger’.

HIGH-FIVE TO ALE TEAM FOR GOING THE EXTRA MILE Five ALE employees from our Abu Dhabi branch have reached new heights by summiting Mount Kilimanjaro in Tanzania, raising over $2,800 in the process by organising a range of activities.

The group wanted to organise team building activities for their branch whilst raising money for the family of their late colleague Cameron Waugh, General Manager at ALE’s Abu Dhabi branch. They started fundraising in August and hosted a bake sale and a family cricket match in September whilst training for the climb.

The team of climbers included Edward Talbot, Cian Dorman, Carlos Moreno, Scott Wheatley, Thomas Wylie and non-ALE employee John Cowie. They trekked for four days and camped overnight in freezing conditions before reaching the summit at 6.30am on the 10th October.

Cian Dorman, Regional Sales Manager who took part, said: “My colleague Thomas Wylie came up with the idea to do the climb. As Cameron was always such an active person, quite an explorer and adventurer, we thought a challenge like this would fit in perfectly with a way of remembering him.

“There was a huge amount of enthusiasm and support between us all and that really gave so much confidence to everyone to reach the summit. We were delighted and relief of course that we all made it, a real sense of achievement! The togetherness and spirit of the group was fantastic - without a doubt the most successful team building exercise I have ever been involved in.”

Alberto Pittaluga IRAQ Regional Manager

TOM STEPHENS – ASSISTANT PROJECT ENGINEERA fan of adventure sports and exploring different countries, Tom has done a tour of different departments and is enjoying the fast-paced environment and seeing the weighings happen on site. He said: “I came here to learn and so far the opportunities have been fantastic. I’ve been getting out on site and have really enjoyed the experience.”

TOM OLVER – ASSISTANT PROJECT ENGINEERWhilst at ALE Tom has worked on the turnkey project at the Carrington CCGT Power Station, UK and is currently on site in Stoke Newington. “I enjoyed working at Carrington, especially because of the large amount of responsibility this brought as it pushed me out of my comfort zone. It’s great getting out to so many different places, posing new challenges week on week. I am having a great time and see myself developing as a person and a better engineer.”

BEN EDWARDS – ASSISTANT PROJECT ENGINEERAs an undergraduate completing a degree in Civil Engineering at Cardiff University, Ben has a passion for travel and has lived in many different countries. “There are so many different projects at ALE and I really enjoy the variety. I’ve just finished working for five weeks in Pembroke, Wales on the heat exchangers project and I’ve also enjoyed working on a few smaller projects with AutoCAD.”

MATTHEW BOTTOMLEY-WISE – ASSISTANT PROJECT ENGINEERMatthew is based in Middlesbrough, UK and worked on the DJH/76 underbridge re-construction in Clitheroe. He said: “The projects I’ve worked on have been interesting and enjoyable, especially the Huldra Topside re-use, which was very ambitious and we all worked to a tight timescale.”

IAN THORPE – ASSISTANT PROJECT ENGINEERWorking on large jobs, such as creating engineering solutions for wind energy projects, through to the smaller projects and bridge replacements, Ian has enjoyed the time spent on site. “Spending time on site has been great as it has allowed me to gain a better understanding of the equipment, how to overcome problems and most of all you can get your hands dirty. Everyone at ALE has been very helpful and it’s rewarding to know I’ve been involved in such innovative engineering projects.”

ALE INVESTS IN FUTURE TALENTChris Hines – Global Recruitment, Learning and Development Manager, said: “Skilled engineers are a crucial part of our continued business success, and over the last 20 years ALE have been very successful in spotting and nurturing the next generation of talent for roles across our business.

In the summer of 2014, we were joined by five engineering undergraduate students who will complete a year in the workplace as part of their degree studies. The successful candidates were selected from over 300 applicants, and came through a rigorous assessment process which tested the skills that they will be using in the workplace. During this time they will all make a significant contribution to the business, whilst getting to grips with ALE’s technically challenging and fast moving environment.”

Here are a few words from each about their experiences so far...

ALE PEOPLE

6.5.

WORLDWIDE HEAVY TRANSPORTATION AND LIFTING

WWW.ALE-HEAVYLIFT.COM

ALE BREAKS RECORD WITH 42,780T JACK UP AND 47,830T LOAD-OUT

ALE COMPLETES FIRST PROJECT USING MEGA JACK 800 IN AMSTERDAM

ALE used its latest design innovation, the Mega Jack 800, for the first time as part of the successful load-out, transport and installation of the new Loenersloote Bridge in Amsterdam.

The Mega Jack 800 was amongst a range of ALE equipment used to remove the old bridge which weighed 1,630t and replace it with the new Loenersloote Bridge, weighing 1,570t, over the Amsterdam-Rijn canal in Nigtevecht.

This exchange project was undertaken in a number of phases and involved the use of the Mega Jack 800, climbing jacks, SPMTs, barges, strand jacks, a heavy skid system, and 700/500t mobile cranes.

The transportation of the new 330t bridge approach span used 20 axle lines of SPMT. The jack-down of the old bridge to demolition height again made use of the versatile Mega Jack 800.ALE has seen the successful

completion of the world’s heaviest jack up and load-out using their innovative Mega Jack System.

The Arkutun Dagi Topside was jacked up for Exxon Neftegaz Limited at the shipyard of Daewoo shipbuilding & Marine Engineering Co. Ltd in Korea.

We jacked the staggering 42,780t topside to a height of 24 metres which was the first project of this kind using our innovative Mega Jack System. The project included the installation of a skid frame (DSF) which the topside was lowered to by the Mega Jack. This was also completed within a day.

Another world record was broken at the final stage of the project, with the load-out of the 47,830t Arkutun Dagi topside. This weight, which was the combination of the 42,695t topside positioned on a 5,135t load-out support frame, was the heaviest to be loaded-out in the world.

ALE’s full scope of work included the stand jack pulling, high capacity modular ballast system and precision 3D barge monitoring.

Russ Jones General Manager for ALE-Offshore Services stated “Working on such a prestigious project really shows how ALE are leading the way with technology. When you are working to such tight tolerances, technology and experience really are the key to success. The precision barge level monitoring system was developed in-house and gives you the comfort factor when you are out there working in the project, knowing the accuracy and reliability of the system allows ALE to push the boundaries and make such projects possible.”

Kees Kompier Executive Director

at ALE said: “This pioneering project is a great achievement for ALE. It clearly demonstrates the strength of ALE’s global capabilities that we are able to jack-up a weight of 42,780t to a height of 24 metres in 11 hours and then load-out a final weight of 47,830t. These are statistics that the industry haven’t been able to witness before and shows that we are now making the impossible possible.”

INNOVATIVE GANTRY SYSTEM MAKES 10,000T DRY DOCKS PROJECT POSSIBLE

Teams from two ALE branches designed a unique gantry system in order to perform a lift and mating operation of a 10,000t topside at Drydocks World for the world’s largest and first semisubmersible HVDC platform DolWin Beta which was constructed at the shipyard.

The gantry system created by ALE’s R&D department in Breda, The Netherlands, and the Middle East branch combined various standard gantry types into one system to make the lift possible. Drydocks World carried out an assessment of topside structural strength, carried out precise weight calculations and designed the heavylift pad eyes to suit the tailor made lifting arrangement of ALE.

Edward Talbot, General Manager at ALE said “For our client this was a first, and as such, a lot of design work, verification and detailed checks were completed to ensure full integrity of the entire system during the operation. Our aim was to execute the lift efficiently with minimal risk to the topside and surrounding yard activities.

“The design meant that our client could not only perform the mating operation inside the dock but also maintain adjacent docking operations with minimal impact to the yard facility during and after lifting and mating completion.”

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PROJECT FOCUS

WORLDWIDE HEAVY TRANSPORTATION AND LIFTING

HSQE

9.

FOCUS ON MARINE ENGINEERING In 2010 ALE’s Marine Engineering Division was established to harness the talent from across the business into one centre of excellence, making the company’s capabilities in this area accessible to our clients on a global scale. This allows us to have a dedicated team available to clients worldwide as an individual service or as part of a bigger project.

The Marine Engineering Division is a team of Naval Architects and Structural Engineers who provide marine engineering services including engineering analysis, research and development, software development and marine operational supervisory on land and at sea, to safely deliver the best solutions for the clients.

Engineering analysis encompasses ship designing, 3D modelling, load-out / load-in analysis, ballasting analysis, mooring analysis, risk analysis, marine transportation analysis, float-off / float-in analysis, launching analysis, flotation & upending analysis, local and global vessel strength check, fender design, jetty design and concepts, sea-fastening design and finite element analysis.

ALE’s Research and Development facility works with the Marine Engineering Division to cater for the industry’s expansion and demand for developing specialized software capable of integrating engineering analysis into an application to be used for engineering calculations and during site execution. Software development includes researching, designing, implementing and testing software that will take part in the project from design phase to execution stage.

Marine operational services include supervision, coordination, and conducting the transport operations from land to sea or from sea to land. On site supervision involves internal / external ballasting system monitoring, load-out / load-in operation (i.e. skid pulling and ro-ro method) and float-off / float-on operation.

Apart from the feasibility studies mentioned, our Marine Engineering Division is also responsible for the preparation of Proposals, Procedures, Technical Writing and Engineering Reports for our clients.

ALE LAUNCHES FIRST AUGMENTED REALITY APP We have launched our first-ever app on the Android and Apple markets for use on smartphones and tablets.

Developed with the marketing department and Global Design Mainframe, an app has been designed that brings the heavylift equipment to life in front of your eyes.

The app is free to download and the experience of viewing the augmented reality model can be enhanced if the bespoke marker is printed. Users can watch as the animation depicts three different operations being executed live: the build up of the AL.SK190, tailing of a vessel and the build up of an FPSO.

Once in use, the user can zoom in and out for details, move the device around for the additional benefit of 360º visibility. More notably, it has the possibility to pause the actions and look in detail at the crane at each step during the different operations.

The app can be accessed in ‘specification mode’, where the benefits of the AL.SK190 crane are highlighted on the crane. Users can also view the product brochure and ALE showreel.

“We are really excited to launch our first ALE app – this is completely new to the heavylift industry and shows how we are leading the way in technology and innovation,” said ALE Animation Engineer Joris Ooms.

“One of the most interesting things is that it isn’t just animation; the user can view all the way around – which not many apps allow. We are delighted with the feedback we have received so far and may look to create more to showcase other equipment from our Innovation Series.”

The app has been on the market since October and is being utilised by ALE staff at exhibitions and events as an effective demonstrative tool.

To download the app free of charge scan the following QR Code or search ‘ALE heavylift’ in Google’s Play Store / Apple’s App Store. It is best viewed with a tablet, considering the amount of detail modeled in the AL.SK190 Crane.

BRANCH FOCUS

ALE TECHNOLOGY

10.WWW.ALE-HEAVYLIFT.COM

ABU DHABI BRANCH ACHIEVE INTERNATIONAL SAFETY CERTIFICATIONALE’s Abu Dhabi branch has achieved OHSAS 18001, which certifies the ALE Safety Management System to the international standard and ensures that ALE are operating best practice. After Madrid, Abu Dhabi are the second ALE branch to receive this certification.

ALE WIN SAFETY AWARD FOR RECORD BREAKING PROJECT Exxon Neftegas Limited awarded ALE ‘Contractor of the Year’ for ‘Excellence in Safety Performance’ on the record-breaking Arkutun Dagi project.

The award was presented at the annual Sakhalin 1 Contractor SSHE Forum held in Yuzhno-Sakhalinsk, Russia.

The award was won on a specific criteria including:

- Safety embedded in system design

- Management commitment and leadership

- Worker involvement and ownership throughout the project

Kees Claasen said: “With safety at the core of what we do at ALE, we are honoured to have received this award. Gaining recognition for our safe working, particularly on a record breaking project shows the value the team put on safety. As with everything we do at ALE, it is a team effort, and with a strong team we can achieve great things.”

The design of the Mega Jack means that working at height and worker / machinery interaction is at an absolute minimum. Any readings and adjustments that are made during the operation are done via a control hub.

In addition to receiving this prestigious award, ALE was invited to attend and present at a conference for safety best practice hosted by Exxon Mobil. ALE was honoured to present to some of the industries giants and looks forward to integrating some of lessons learned from the variety of case studies presented.

WORLDWIDE HEAVY TRANSPORTATION AND LIFTING

Case studies – Australasia

12.11.

CAR DUMPER INSTALLATION PROJECT, AUSTRALIAOVERVIEW: ALE has successfully completed the site transport and installation of two 400t car dumper cells and a 50t dust enclosure using the largest ALE crane in Australia. The whole operation took three days.

SERVICES REQUIRED: The car dumper cells were installed using a LR11350 crane – ALE’s largest crane currently operating in Australia.

The car dumper cells were installed in a very tight concrete structure, surrounded by structures and machinery, which meant that there was limited space for the positioning and

manoeuvring of the crane.

ALE designed a specialist lifting operation to solve this challenge and comply with the site requirements. Twenty-eight axle lines of SPMT were used to pick up each car dumper, which were stooled 500m from the installation position, and deliver them below the hook.

Once under the hook, the car dumper cells were connected to the rigging arrangement and disconnected from the transport frame. The crane crawled to install the cell, clearing the supporting structures by around 10mm each side.

The dust enclosure was erected close to its final position and needed to be uprighted. The rigging arrangement was designed to include chain blocks to allow the uprighting.

FINAL LOAD-OUT COMPLETED FOR THE GLNG PROJECT, PHILIPPINESOVERVIEW: ALE’s branch in the Philippines executed the load-out of the last two modules weighing 1,925t and 966t.

SERVICES REQUIRED: The project which started in January 2013, involved the load-out of 111 modules ranging from 31t - 1,925t, alongside the transportation of numerous vessels and equipment.

The first load-out was completed in April 2013 with the final load-out in August 2014. ALE utilised SPMT axles for the load-outs, with 104 axle lines required for the heaviest piece.

During the project, the delivery of a vessel was delayed and ALE proposed a methodology for skidding the vessel to avoid impacting the schedule of module assembly. Weighing 135t, the vessel was skidded at 5m height using a push and pull system, hydraulic jacks and hyjack frame.

Case studies – Europe

CARRINGTON CCGT INSTALLATION, UKOVERVIEW: ALE was awarded a full turnkey package for the transportation and installation of associated heavy equipment for the Carrington CCGT Power Station. This included the installation of the gas turbine and generator units which ALE successfully completed with its Lift n Lock system.

SERVICES REQUIRED: Prior to the installation of the gas turbine generator, the ALE Lift n Lock system was rigged within the turbine hall of the power station.

ALE then transported the 360t gas turbine generator on 24 axle lines of SPMT from the laydown area on site to the installation area in the turbine hall. Skidding equipment and an ALE 635t capacity Lift n Lock system were used to install the generator on a plinth 4.5m above ground level.

The 385t gas turbine unit was transported on site by SPMT and was skidded 9.5m into position. It was then jacked down and aligned on the base plates.

ELDFISK 2/7S TOPSIDE PROJECT, NORWAYOVERVIEW: ALE completed the load-out of the Eldfisk 2/7s topside modules in Stord, Norway.

SERVICES REQUIRED: The project spanned over 12 months and involved weighing, jacking, SPMT site moves, load-ins and the final load-out of the completed modules. The weights of the various modules ranged from 1,600t to 11,500t.

The final operation involved the load-out of the two completed modules onto the Saipem S44 barge. The C00 Process module weighed 11,500t and the UQ0 Utility/LQ module 7,000t.

The operations used over 400 axle lines of SPMT and the ALE hydraulic ballast pump system with its 1,000cu.m/hour pumping capacity.

ALE worked very closely with the client during the engineering phases to ensure a smooth and successful delivery. ALE was responsible for the full design and engineering of each activity and included the ballasting designs for the load-in/outs. This also involved heavy involvement in HAZOP and SJA meetings along with site specific meeting pre-operation to ensure all on site teams worked together coherently.

CLICK HERE TO SEE MORE CASE STUDIES FROM THIS REGION CLICK HERE TO SEE MORE CASE STUDIES FROM THIS REGION

WORLDWIDE HEAVY TRANSPORTATION AND LIFTING

Case studies – Middle East and Africa

14.13.

INSTALLATION OF A STEEL BRIDGE IN BUENOS AIRES, ARGENTINAOVERVIEW: ALE has successfully completed the installation of a steel bridge, weighing 155t, over Avenida General Paz and 25 de Mayo in Buenos Aires.

SERVICES REQUIRED: ALE was tasked to mount a new steel bridge whilst avoiding any obstruction to the heavy vehicle flow on one of the most used highways in Buenos Aires - Avenida General Paz.

The bridge was prepared parallel to the highway, at the service road level. The assembly operation consisted of taking the bridge from its original position, turning it 90 degrees and carrying it to its final position, where it was descended over the brackets onto the final supports.

In order to do this, two gantry structures were designed with four 90t skidshoes as their main beams. The gantries were then assembled on two conventional trailers which were propelled by two prime movers and linked together using a beam for rigidity as they could work as a single unit. This is the first bridge installation by ALE’s Argentina

branch to be installed in this way; where conventional trailers have been used instead of SPMTs, which highlights the high level of engineering involved.

The installation took 1.5 hours and the manoeuvre was performed in 11 hours, within the time limit and thus avoiding highway interruption.

TRANSPORTATION AND INSTALLATION OF MODULES IN RIO DE JANEIRO, BRAZIL OVERVIEW: ALE installed an accommodation module, weighing 1,538t, and a service module, weighing 702t, on the Petrobras P-74 FPSO site in the EEP shipyard.

SERVICES REQUIRED: The challenge was to achieve this in the shortest possible timescale in order to maximise the cost efficiency of the project. The engineering solution was the use of the AL.SK190 crane. Its 118.5m main mast was positioned to reach and lift pieces from one single point without the need for the crane to be repositioned or the FPSO to be removed from the dock. The AL.SK190 crane performed three lifts to install the accommodation module, service module and the helideck. ALE completed a range of site moves using a total of 56 axle lines of SPTs.

Case studies – Americas and Canada

JALILAH B FIELD DEVELOPMENT PROJECT, UAEOVERVIEW: ALE has successfully completed the weighing, transportation and load-out of a boat landing, weighing 150t, and jacket, weighing 414t.

SERVICES REQUIRED: The jacket was weighed using 200t load cells and jacks. The heavylift items were then transported using 44 axle lines of SPMT and loaded onto a barge through four stages of ballasting using ALE ballast and de-ballast pumps.

LPG4 KUWAIT CITY, KUWAITOVERVIEW: ALE was selected to complete the transportation and installation of 118 pieces including a De-ethaniser tower, weighing 1,315t, at a refinery in Kuwait.

SERVICES REQUIRED: Planning for the installation of the tower began almost a year prior to the operation. The transportation presented the biggest challenge with route surveys and route modifications required prior to the transportation by SPMTs. On-site the lifts

and installations by the AL.SK190 were completed using a fixed tailing frame for the two largest pieces and the CC2800-1 for the remaining pieces. The success of the project was down to the AL.SK’s ability to independently install all pieces from one position.

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WORLDWIDE HEAVY TRANSPORTATION AND LIFTING

issue 08

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