Lifting Plan and Rigging Study-Amine ReboilerE-1260

Lifting plan & Rigging Study- Amine Reboiler E-1270

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Lifting plan & Rigging StudyE-1260 Amine Reboiler

Category of Lift: Complicated


Yes N/A Components of lift planLift Plan Checklist (exhaustive)

Plan View of Facility Layout

Routing Sketch of Equipment Travel into Plant

Load Manifest & Contingency Plan

Plan View Drawings for both pick up and Drop points ( Exclusion zones, Pick up radius, Drop Radius, Counter Weight Clearances, Out-rigger Clearances, Load Clearances from nearby equipment, Counter weight swing arc, Path of lift, Tag lines, Signal man positioning)

Elevation View Drawings for maximum radius (Boom length, boom angle, Boom to Load Clearance, Boom angle, Load Clearances from ground and nearby equipment, Hook Block to ATB Clearance, Counter weight clearances, Boom Arc)

Rigging Gear Detail and Configuration

Percentage usage of each crane (s) capacity at maximum radius

Reaction Forces at lifting points and Center of gravity calculations

Rigging gear stress calculation (sling tensions, mode factors etc.)

Cribbage Selection

Others reference documents (Lifting Equipment inspection/Test Certificates, Personnel Competency Certificates, Lifting Equipment Pre-use Inspection Checklists, Hazard Identification & Task Risk assessments, Permit-to-work, Load Charts, Range diagrams)

Lifting Plan Content Checklist- Tick as required

Lifting plan & Rigging Study- Amine Reboiler E-1270Lifting Plan Checklist (exhaustive)

ITEMS TO ADDRESS WHEN PLANNING LIFT (check all highlighted in yellow prior to lift) YES N/A

Has the responsible manager and the Safeguards & Security Division been notified of movement of the load to the lifting site

Has the load transport route to the lift site been checked for overhead obstructions? Are there any bridges, culverts, pipe ways to cross? Are they structurally capable of safely supporting the transport loads?

Are the minimum actual clearance between the load and the boom during the lift within allowed limits? √

Has the radius been double-checked by measuring in the field?

Will spreaders and other rigging hardware remain safely clear of the boom, the load, and other objects at all times during the lifting operation? √

Have obstructions been identified in the lift path and swing path?

Can the outriggers be deployed as per manufacturer’s load chart requirements? √

Can rigging personnel safely control and manipulate the load throughout the lifting path? √

Are the crane’s operational safety alarms functioning properly?

Has a drawing showing the elevation of the crane during the lift as well as all clearances been developed (boom to load, and load to other obstructions)?

√

Have all repairs or modifications to the crane been made in accordance with manufacturer’s written instructions, and are they so certified?

Has the agreed nondestructive examination (NDE) of crane components been done and documented?

Is the correct crane load chart for current lift conditions in the cab?

Is there adequate headroom to ensure that the manufacturer’s minimum allowable two-block distance is maintained for the configuration of the reeve used?

√

How was the weight determined when developing the lift plan? Has any contingency been added to calculated weights? √

Has an accurate load weight determination been made before the lift to confirm calculated weight? √

Has all the rigging hardware been included in the weight calculations? √

What are the maximum loads per unit area imposed by the cranes on the soil/facility floor? Is the soil-bearing capacity adequate to safely support crane loads?

√

Lifting plan & Rigging Study- Amine Reboiler E-1270Lifting Plan Checklist

ITEMS TO ADDRESS WHEN PLANNING LIFT (check all highlighted in yellow prior to lift) YES N/A

How was Center of Gravity determined? Is it marked on the load? Is it shown on the lift plan drawings? √

Has the liquid/semi solid inside the load that could shift during the lift been considered?

Is the surface area large enough to create unusual control problems in the wind?

If lifting a dressed device, has the insulation absorbed any water, has this been incorporated in load manifest? √

Have all anchor bolts and fasteners been removed?

Has all rigging hardware been selected to work within the manufacturer’s Safe Working Load? √

Have sling angles flatter than 45 degrees been avoided? √

Have softeners been used to protect the rigging where sharp corners could cause damage? √

Are shackles, pad eyes, eyebolts and hooks always used in such a manner as to avoid side bending in the hardware? √

Is there a plan for removing lifting tackle from the load after it is erected? √

Have all lifting appliances and accessories been inspected before use by a competent personnel ?

Are the shackle pins and lifting eyes compatibly sized? √

Is the rigging arranged to have the crane hook directly over the load’s center of gravity with the load hanging level? √

Has the lift plan been reviewed with the crane operator, riggers, and others involved in the lifting operation?

Has the wind speed been measured by anemometer? Is the wind speed within acceptable limits?

Is adequate lighting equipment available for use √

Have emergency procedures been determined and communicated to all personnel involved in the lifting operation?

Is the load fragile enough to require lifting from a “strong back” frame or from multiple attachment points to prevent load damage? √

Has any required nondestructive testing been done to assess the quality of welds attaching lifting lugs, pad eyes, trunnions, etc.?

Is there enough clearance between the load and the lifting lug/pad eye to get the nut on the shackle pin?

Is there enough clearance between wire rope slings and equipment present on load skid?


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Load Manifest-

Load Manifest

Description Unit Weight Kg (s)

Amine Contactor Dry Weight 17360

Lifting accessories weight (both cranes) 200

Hook Block weight (100 tonne crane) 1000

whip line weight 100

Total Weight 18660

10 % Contingency 1866

Total Weight to be lifted 20526

Lifting plan & Rigging Study- Amine Reboiler E-1270Facility Layout (Scaled drawing)-

Lifting plan & Rigging Study- Amine Reboiler E-1270Facility Layout (Scaled drawing)-


List of equipment to be lifted/removed prior to lifting E-1260 (Amine Reboiler)

1. Reflux Accumulator V-1274

2. Amine vent drain pump P-1270 (also demolish its containment)

3. All interconnecting piping spools between Amine still column (D-1202) and Amine reboiler E-1260

4. All overhead interconnecting pipe spools between E-1262, V-1274, D-1202, V-1278

5. Removal of all pipe supports for above mentioned pipe spools

6. Removal of all protruding pipe support bolts as mentioned above.

Facility Layout (Scaled drawing)- Necessary requirements before lifting D-1200

Lifting plan & Rigging Study- Amine Reboiler E-1270Amine Reboiler E (Scaled drawing)-

Fire Tubes

Lifting plan & Rigging Study- Amine Reboiler E-1270Amine Reboiler E (Scaled drawing)-Center of Gravity Calculations

8 tonnes(Outer Shell)10 tonnes

(Fire tube)

Item Dft

WtTe

Wt x D

Fire tube 20.75 10.0 207.5

Outer Vessel

26.91 8.0 215.28

Totals 47.66 18.0 422.78

Center of gravity distance from point A= 422.78/18 = 23.48 ft from reference line

Reference line

Lifting plan & Rigging Study- Amine Reboiler E-1270Amine Reboiler E (Scaled drawing)-Rigging Gear Arrangement

Web Sling, Basket 90 degree, length 25 ft

Center of Gravity

Lifting plan & Rigging Study- Amine Reboiler E-1270Reactions at Point A and Point B

Center-of-gravity

Vertical Reaction force R1 at Lifting point

Weight, W

Reaction force R2

Distance, NDistance, M

Sample Calculation:

Weight of Load = 18000 kgDistance M = 12.5 ft Reaction R1 = ?Distance N = 18 ft m Reaction R2 = ?

We know that Moment = Force X distanceAnd , clockwise moment = anti clock wise momentAnd, Upward Force = Downward Forces

Taking moment at R1 ;Clockwise moment = anti clockwise momentW X M = R2 X (M+N)R2 = (W X M) / (M+N)R2 = ( 18000 X 12.5 ) / ( 30.5 )R2 = 7377 kgs (Reaction at Point B)Upward forces = Downward forcesW = R1 + R2R1= W – R2 = 18000 – 7377 = 10622.9 kgs (Reaction at point A)

18.0 tonnes

A B

Lifting plan & Rigging Study- Amine Reboiler E-1270Sling Tension at Point A and Point B (wire rope slings and Chain Sling)

Lifting plan & Rigging Study- Amine Reboiler E-1270Sling Tension at Point A (Web sling basket at 90 degree)

Total length of Web Sling Required for a 90 deg Basket Hitch =

15 ft +4.5 ft+4.5 ft = 24 ft

Reaction at point A is 10622.9 kgs

Sin 70 = R1/T1

T1= 10622.9/sin70

T1= 11304.5

Since it is a 90 deg Basket hitch

The mode factor will be 1.4

So the Sling required at point A

Should be atleast 11304.5/1.4 =

8074 kgs

Therefore a 10 tonne, 25 ft long

websling will be adequate to safely lift the Amine Reboiler.

There is no need to calculate the websling tension at point B as the share load is already 7377 kgs which is less than what we calculated above

Sling Angle 70 deg at point A

Web sling Tension, T1

Reaction

Point A, R1

Lifting plan & Rigging Study- Amine Reboiler E-1270Facility Layout (Scaled drawing)- Pick up Point-

100 tonne crane

With 80 ft boom.

Rear Low Bed Trailer – 40 ft bed

Tag line

Exclusion Zone

Lifting plan & Rigging Study- Amine Reboiler E-1270Facility Layout (Scaled drawing)-Drop point

100 tonne crane

With 80 ft boom.

Rear Low Bed Trailer – 40 ft bed


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Side view elevation (scaled drawing)- At maximum radius

Boom Length 83 ft

100 tonne crane

With 80 ft boom.

Boom Length: 80 ft

Work Radius: 31 ft

Boom angle (worst case): 66 deg

Boom to Amine Contactor Clearance: 25 ft

Foundation to Vessel clearance : 2 ft

Hook block to ATB clearance : 30 ft


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Rigging gear detail

Rigging Gear Detail (both Cranes)

Description Unit Weight Kg (s)

Quantity Total Weight (KGS)

15 ton SWL, Soft eye wire rope sling, 15 ft length

15 02 100

17 t SWL Crosby bow shackles

10 04 40

15 ton SWL, Adjustable Chain Sling, Maximum length 15 ft

50 02 100

Webbing Sling 25 ft, 10 ton, 10 inch wide

15 02 30

Hook Block Weight 1000 01 1000

Total Weight of lifting accessories 1270 kgs


1919

% usage of Crane

Load description

Boom Length (ft)

Pick up radius (ft)

Drop Radius (ft)

Worst Case Radius (ft)

Boom angle (worst case)(Deg)

Total weight load, MT

Safe Lifting Capacity, worst case (MT)

% usage worst case

Amine Reboiler

80.0 31.0 29.0 31.0 66.0 20.52 54

Lifting plan & Rigging Study- Amine Reboiler E-1270Cribbage Selection-360 tonne crane

Rule of Thumb formula and calculations for cribbage area:

Sample Calculation:Soil Type : Sandy Gravel1 kN = 1000 N = 100 kg Mass of Crane = 100000 kgs or 1000KNMass of Load = 20526kgs or 205 KN

Area of Cribbage = 0.65 X (1205) / 239.4

Area of Cribbage = 3.27 m² or (1.8 m by 1.8 m) or ( 6.0 ft by 6.0 ft by at least 4 inch thick)

Soil Bearing Capacity Table

Type of SoilLoad Bearing

(Pounds Per Square Foot)

Load Bearing (kPa)

Rock w/ Gravel 6,000 psf + 287.28

Gravel 5000 psf 239.4

Sandy Gravel 5000 psf 239.4

Sand 3000 psf 143.64

Silt Sand 3000 psf 143.64

Silt Gravel 3000 psf 143.64

Gravel w/ Clay 3000 psf 143.64

Clay 2000 psf 95.76

Sandy Clay 2000 psf 95.76

Silt Clay 2000 psf 95.76

We have selected this value as ground will be prepared for this crane by leveling, grading and compacting the soil followed by adding a layer of rock/morum.

Wooden pad thickness should be at least 4 inch

Lifting plan & Rigging Study- Amine Reboiler E-1270Load Chart- 100 tonne crane

Documents

Lifting Plan and Rigging Study-Amine ReboilerE-1260