CASE STUDIES AMERICAS - ALE€¦ · Because of a close working relationship and proven track record in operations such as this, the client had confidence in ALE’s abilities to successfully

ALE DELIVERS INNOVATIVE SOLUTION AND CUSTOMISED SUPPORT PACKAGE TO UPSCALE MEXICAN YARD

SECTOR: OFFSHORE

KEY BENEFITS: QUICK OPERATIONS » INNOVATION » REDUCED COSTS » BESPOKE ENGINEERING » REDUCED RISK

PROJECT: ALE has delivered an integrated solution to help complete a phase of a major offshore project in Mexico.

The global heavy lifting contractors were tasked to perform the weighing, jacking and load-out of the jacket and the platform.

EFFICIENT JACKING SYSTEM

The first stage of the three-phased project involved the 14m-high jack-up of the topside, weighing over 13,000t, using ALE’s innovative Mega Jack system. As the Mega Jack had its own starter beams, and has quicker assembly and jacking speeds, it is much more efficient than other systems on the market.

ALE configured the Mega Jack with eight towers, each with 5,200t capacity. This provided the strength needed to lift such a heavy weight whilst evenly distributing the ground loading pressure. The topside was jacked-up to 14m high in stages. Upon reaching the first jacking phase at 5.5m high, the client could access the forklifts under the topside, which was a major advantage as they could continue operations and optimise the project schedule.

SPECIALIST OFFSHORE TEAM

For the load-out of the topside, ALE – Offshore Services was the specialist team who designed and supplied the rapid ballasting system, with a system capacity of 16,000 Cu.M/Hr, as well as the associated ballast pipework specifically for this operation.

With a combined weight of almost 17,000t, ALE’s experienced offshore team worked in two shifts to pull the topside a total distance of 196.63m. By using strand jacks and kicker jacks to pull the topside onto the client’s barge, ALE completed the load-out in a timely manner.

The final stage involved the floatover in the Gulf of Mexico. Six 24PS ballast pumps, 18 10PS de-ballast pumps and ten 380HP HPUs were installed onto the client’s barge, along with associated ballast pipework.

Health, safety and the environment (HSE) was a paramount consideration throughout and underpinned the entire project. ALE ensured all operations were supervised centrally in real-time to ensure operational flow.

“This is a fantastic achievement for all of the ALE teams involved. Throughout this project, we have established a strong on-site partnership to meet our client’s technical and operational needs,” explained Simon Armstrong, Project Manager for ALE – Offshore Services.

“By finding a solution that could integrate our systems easily with the client’s needs, we delivered effective methodology, and the proven upscaling of the yard makes it a more attractive site for future operations.”

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LIFTING EXPERTISE HELPS SOUTHEAST TEXAS PLAN FOR FUTURE POWER NEEDS

SECTOR: OIL, GAS AND PETROCHEMICALKEY BENEFITS: FAST DEPLOYMENT » SUPPORTS MODULAR CONSTRUCTION » PROJECT SCHEDULE PROTECTED

PROJECT: The Houston metropolitan area has seen population growth far in advance of the US average for decades, growing some 35% since 1990. Predicting a shortfall of 1.2 gigawatts without action by 2022, it sought to concentrate existing power generation facilities through the construction of the new Montgomery County Power Station adjacent to the existing facilities.

With the start of the operation due two years after breaking ground, maintaining high levels of efficiency to keep the project to schedule was imperative. This required experience in undertaking complex lifts in an environment where space is increasingly a factor.

ALE’s experience, honed during projects on both existing and newbuild plants, was vital in lifting many of the plant’s major components. Their scope was to lift a total of 29 modules ranging from 200t (220 US tons) to 285t (315 US tons), over a four-month period.

The most complex of these lifts was the verticalization of two Heat Recovery Steam Generator modules. Measuring around 30m x 4m x 4m (98 ft x 13ft x 13ft), this required a tandem lift procedure involving both 750t (827 US tons) and 600t (660 US tons) capacity ALE cranes.

Notable additional modules ALE lifted during this period include two gas turbines, three transformers, two generators and a steam turbine. Once complete, these modules will help to deliver 993 MW of power to Texan homes.

ALE supplied an expert crew to undertake these lifts, backed up by its global power generation projects team. Key equipment included three crawler cranes rated at 800t (880 US tons), 600t (660 US tons) and 250t (275 US tons) capacity, SPMTs and a full jack and slide system, allowing complex positioning manoeuvres.

This equipment is deployed strategically around the globe to provide the highest levels of availability for active projects. For this reason, the crawler cranes were delivered and assembled on site within a month of the project award date.

The Montgomery County Power Station will begin operation in 2021, creating 25 permanent jobs and have a predicted $1 billion of total economic impact on the region.

INNOVATIVE JACKING SOLUTION SAVES TIME AND SPACE DURING ROOF LIFT, USA

SECTOR: CIVIL

KEY BENEFITS: INNOVATION » OPTIMISED SPACE » CO-ORDINATION WITH THIRD PARTIES

PROJECT: ALE’s ability to provide innovative and specially-tailored heavylifting solutions enabled them to provide an alternative lifting solution to raise a roof section, weighing 400t (441 US tons), for an amphitheatre in Milwaukee, USA.

ALTERNATIVE JACKING SOLUTION

There was minimal space available at the site, so ALE devised a jacking solution using eight strand jacks to lift a section of the roof. Utilising their global resources and engineering expertise, ALE modified existing beams to specially adapt them for use as outrigger beams on the heavylifting project. The strand jacks operated simultaneously to gradually lift the roof section to a height of almost 20m (65 ft).

One unexpected challenge on the project was the weather, which was more severe than usual for the area. Temperatures fell to -30°C (-22°F) overnight and temporarily prevented the client from continuing welding work. ALE’s solution enabled the roof section to be securely held in place, with the weight supported for almost two weeks – three times longer than originally planned - before the swift lifting operation was completed.

CLOSE COMMUNICATIONS

ALE worked closely with the client, who supplied the supporting structure for the operation, and regular co-ordination meetings ensured smooth communication between the project’s various contractors.

As ALE’s innovative jacking solution required less equipment than other techniques, it had a smaller footprint and this alternative lifting method also enabled the roof section to be lifted quicker, minimising the impact on other simultaneous operations.

The roof lift is part of a series of renovations that will increase the amphitheatre’s capacity so that the venue can produce more complex shows for larger audiences.

PROJECT COSTS CUT USING ALE’S ENGINEERING DESIGN IN MEXICO

SECTOR: MINERALS AND METALS

KEY BENEFITS: COST SAVING » TIME REDUCTION » EXTENSIVE EQUIPMENT

PROJECT: ALE’s in-house engineering team has used its expertise to save site costs and devise a lifting design that optimised the site during multiple crane lifts in Silao, Mexico.

ACCURACY SECURES TRIPLE LIFT

The scope involved lifting three plant modules, weighing up to 314t each, as well as a bridge crane and roofing, using an LR11350 crawler crane with P boom.

The items had been built on provisional foundations. Following a load test, each module was rotated 180° and then lifted over and above the east side of the building, 72m high. They could then be installed from above and were lowered into the plant. Accuracy was vital as the modules were discharged on top of each other and the client then connected them by screwing them together.

SMALL FOOTPRINT CUTS COSTS

All the lifts, including the overhead crane and roofing, were carried out consecutively and completed in six days. ALE’s choice of crane configuration and its small footprint minimised congestion onsite and enabled construction work to continue. As the client was able continue other work without crane pad interference, overall project costs and build schedules were optimised.

Because of a close working relationship and proven track record in operations such as this, the client had confidence in ALE’s abilities to successfully complete the multi-lift project in Mexico.

Once complete, the site will become a new steel mill that will be used to supply to all the car plants in the surrounding areas.

CRANE LIFTING EXPERTISE ENSURES SWIFT INSTALLATION OF A COLD BOX, USA

SECTOR: CIVIL

KEY BENEFITS: CLOSE COORDINATION » SWIFT INSTALLATION » BESPOKE EQUIPMENT

PROJECT: ALE has drawn on its experience in delivering tightly planned, efficient heavylifting projects to complete the lifting of a cold box, weighing 272t (300 US t), in North Carolina, USA.

The cold box measured 45.7m x 9.1m x 6.1m (150ft x 30ft x 20ft) and two crawler cranes were required to lift it from its initial horizontal position. ALE supplied spreader bars and rigging that were designed specifically for the lift and were used to connect the box. A 750t capacity crane with a superlift ballast wagon was used to lift from one end while a 300t capacity crane was used as the tail crane to simultaneously lift from the other.

Once the cold box had been lifted into position, ALE set it down onto a permanent foundation. The lifting operation was completed within a few hours.

Levi Lawrence, Operations Manager, said, “We’re delighted to be bringing ALE’s trusted heavylifting services to the US. Lifts like these demonstrate ALE’s ability to perform a variety of lifts anywhere in the world while drawing on our diverse range of expertise.”

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