Lifting plan & Rigging Study- Amine Reboiler E-1270

Lifting plan & Rigging Study E-1260 Amine Reboiler

Category of Lift: Complicated

Lifting plan & Rigging Study- Amine Reboiler E-1270

Lifting Plan Content Checklist- Tick as required

Yes N/A

Components of lift plan

Lift 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 & Rigging Study- Amine Reboiler E-1270

Lifting Plan Checklist (exhaustive) ITEMS TO ADDRESS WHEN PLANNING LIFT (check all highlighted in yellow prior to lift) 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?

YES

N/A

Have obstructions been identified in the lift path and swing path?
Can the outriggers be deployed as per manufacturers load chart requirements? Can rigging personnel safely control and manipulate the load throughout the lifting path? Are the cranes 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 manufacturers 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 manufacturers 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-1270

Lifting Plan Checklist ITEMS TO ADDRESS WHEN PLANNING LIFT (check all highlighted in yellow prior to lift) 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 manufacturers 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 loads 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.?

YES

N/A

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?

Lifting plan & Rigging Study- Amine Reboiler E-1270

Load Manifest-

Load Manifest
Description Amine Contactor Dry Weight Lifting accessories weight (both cranes) Hook Block weight (100 tonne crane) whip line weight Total Weight 10 % Contingency Total Weight to be lifted Unit Weight Kg (s) 17360 200 1000 100 18660 1866 20526

Lifting plan & Rigging Study- Amine Reboiler E-1270

Facility Layout (Scaled drawing)-

Lifting plan & Rigging Study- Amine Reboiler E-1270

Facility Layout (Scaled drawing)-

Lifting plan & Rigging Study- Amine Reboiler E-1270

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

List of equipment to be lifted/removed prior to lifting E-1260 (Amine Reboiler) 1. 2. Reflux Accumulator V1274 Amine vent drain pump P-1270 (also demolish its containment) All interconnecting piping spools between Amine still column (D-1202) and Amine reboiler E-1260 All overhead interconnecting pipe spools between E-1262, V-1274, D-1202, V-1278 Removal of all pipe supports for above mentioned pipe spools Removal of all protruding pipe support bolts as mentioned above.

3.

4.

5.

6.

Lifting plan & Rigging Study- Amine Reboiler E-1270

Amine Reboiler E (Scaled drawing)-

Fire Tubes

Lifting plan & Rigging Study- Amine Reboiler E-1270

Amine Reboiler E (Scaled drawing)-Center of Gravity Calculations

Item

D ft 20.75

Wt Te 10.0

Wt x D

Fire tube

207.5

Outer Vessel Totals

26.91

8.0

215.28

47.66

18.0

422.78

10 tonnes (Fire tube)

8 tonnes(Outer Shell)

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-1270

Amine 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-1270

Reactions at Point A and Point B

Vertical Reaction force R1 at Lifting point

Reaction force R2

Center-of-gravity

Distance, M

Distance, N Weight, W

Sample Calculation: Weight of Load = 18000 kg Distance M = 12.5 ft Reaction R1 = ? Distance N = 18 ft m Reaction R2 = ? We know that Moment = Force X distance And , clockwise moment = anti clock wise moment And, Upward Force = Downward Forces Taking moment at R1 ; Clockwise moment = anti clockwise moment W X M = R2 X (M+N) R2 = (W X M) / (M+N) R2 = ( 18000 X 12.5 ) / ( 30.5 )

18.0 tonnes

R2 = 7377 kgs (Reaction at Point B)

Upward forces = Downward forces W = R1 + R2

R1= W R2 = 18000 7377 = 10622.9 kgs (Reaction at point A)

Lifting plan & Rigging Study- Amine Reboiler E-1270

Sling Tension at Point A and Point B (wire rope slings and Chain Sling)

Lifting plan & Rigging Study- Amine Reboiler E-1270

Sling Tension at Point A (Web sling basket at 90 degree)

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.

Web sling Tension, T1

Reaction
Point A, R1

Total length of Web Sling Required for a 90 deg Basket Hitch = 15 ft +4.5 ft+4.5 ft = 24 ft

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

Lifting plan & Rigging Study- Amine Reboiler E-1270

Facility Layout (Scaled drawing)- Pick up Point-

Rear Low Bed Trailer 40 ft bed

100 tonne crane With 80 ft boom.

Exclusion Zone Tag line

Lifting plan & Rigging Study- Amine Reboiler E-1270

Facility Layout (Scaled drawing)-Drop point

Rear Low Bed Trailer 40 ft bed

100 tonne crane With 80 ft boom.

Lifting plan & Rigging Study- Amine Reboiler E-1270

Side view elevation (scaled drawing)- At maximum radius

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 Boom Length 83 ft

100 tonne crane With 80 ft boom.

17

Lifting plan & Rigging Study- Amine Reboiler E-1270

Rigging gear detail

Rigging Gear Detail (both Cranes) Description 15 ton SWL, Soft eye wire rope sling, 15 ft length 17 t SWL Crosby bow shackles 15 ton SWL, Adjustable Chain Sling, Maximum length 15 ft Webbing Sling 25 ft, 10 ton, 10 inch wide Unit Weight Kg (s) 15 Quantity 02 Total Weight (KGS) 100

10 50

04 02

40 100

15

02

30

Hook Block Weight

1000

01

1000
1270 kgs

Total Weight of lifting accessories

18

Lifting plan & Rigging Study- Amine Reboiler E-1270

% 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

19

Lifting plan & Rigging Study- Amine Reboiler E-1270

Cribbage Selection-360 tonne crane

Soil Bearing Capacity Table

Type of Soil Rock w/ Gravel Gravel Sandy Gravel Sand Silt Sand Silt Gravel Gravel w/ Clay Clay Load Bearing (Pounds Per Square Foot) 6,000 psf + 5000 psf 5000 psf 3000 psf 3000 psf 3000 psf 3000 psf 2000 psf Load Bearing (kPa) 287.28 239.4 239.4 143.64 143.64 143.64 143.64 95.76

Wooden pad thickness should be at least 4 inch

Sandy Clay
Silt Clay

2000 psf
2000 psf

95.76
95.76

Rule of Thumb formula and calculations for cribbage area:

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.

Sample Calculation: Soil Type : Sandy Gravel 1 kN = 1000 N = 100 kg Mass of Crane = 100000 kgs or 1000KN Mass of Load = 20526kgs or 205 KN Area of Cribbage = 0.65 X (1205) / 239.4 Area of Cribbage = 3.27 m or (1.8 m by 1.8 m) or ( 6.0 ft by 6.0 ft by at least 4 inch thick)

Lifting plan & Rigging Study- Amine Reboiler E-1270

Load Chart- 100 tonne crane