ALE, P.I. Los Frailes. Naves 101-106 - Ctra Alcalá de Henares a Daganzo, km 9 - 28814 Daganzo (Madrid), Spain

Tel:+ 34 91 8845403 Fax:+ 34 91 8845840 Web:www.ale-heavylift.com

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Installation of heavy cargo in two gas combined-cycle power plants in Beni Suef and New Capital

Project: Transportation and installation of heavy cargo to two gas combined-cycle power plants

Location: New Capital and Beni Suef, Egypt

Equipment: 40 axle lines of conventional trailers in a 4 file 20 configuration, 24 axle lines of SPMT in a 4 file 12 configura-tion, three primer movers (one Trojan truck + two MAN trucks), three skidding gantries (four 200t strand jack units and two SS300 push-pull units each)

Weights: 16 gas turbines weighing 486t , 16 gas turbine generators weighing 396t and eight steam generators weigh-ing 396t

Key Features: Reduced schedule

ALE was awarded with the installation of all heavy cargo of mechanical equipment for the newly constructed gas combined-cycle power plants in Beny Suef and New Capital, in Egypt. As the largest combined cycle project in the world, each plant will be made up of 8 gas blocks and 4 steam blocks and will

generate 4,800MW of power. The project started in mid-April, focusing on the Beni Suef plant. By the end of June, in just 10 weeks and despite coinciding the operation with the holy month of Ramadan, ALE had installed 6 gas turbines and 6 generators in Beni Suef. In New Capital, 2 gas turbines and 2 gas turbine generators were installed. ALE installed the cargo using non-standard skidding gantries and all movements inside the plant were carried out using 24 axle lines of SPMT in a 4 file 12 configuration. The gantry structure has been designed for this project to avoid any interferences with the foundations. The lifting system is defined by four 200t strand jack units and the skidding system consisted of skid tracks on spreader beams and 4 push-pull units.

Lifting of the gas turbine in New Capital Installation of a gas turbine generator in Beni Suef

ALE, P.I. Los Frailes. Naves 101-106 - Ctra Alcalá de Henares a Daganzo, km 9 - 28814 Daganzo (Madrid), Spain

Tel:+ 34 91 8845403 Fax:+ 34 91 8845840 Web:www.ale-heavylift.com

The procedure was as follows: The SPMTs carried the cargo underneath the gantry. The cargo was connected to the lifting units with special grommets of 166t (maximum). The cargo was lifted above foundation level and the SPMTs were then released. The gas turbines and gas turbine generators were skidded until they were over their foundations. They were then lowered 500mm over their final position. The final adjustments were made using pulling equipment, according to manufacturer requests. The cargo was lowered until they were in position.

Gantry movements between blocks were performed using 24 axle lines of SPMT in a 4 file 12 configuration, and as it only takes 2 hours it avoids wasting time between block installations. The gantries were also specifically designed for these movements, by using removable devices installed in the gantry legs allowing the installation of transport beams. Because of the different position of the lifting points for the gas turbines and the gas turbine generators, the gantries were designed with removable main beams and lifting points that can be switched according to the piece to be lifted. A second gantry was delivered to Beni Suef Power Plant on request of the client. Each gantry had a different configuration to save time, one for gas turbines and another for gas turbine generators. ALE then needed to move the gantries between blocks to install the cargo. These movements were made using SPMTs, which benefited the project as it is easy to shift the gantries and no auxiliary means are needed.

Installation of a generator in New Capital

Installation of a turbine in New Capital

Turbine and generator installed Installation of a turbine in Beni Suef