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Lifting Procedure of Generator Stator

DOCUMENT NO: P-T3109-RED-005

 DOCUMENT NO. :
LIFTING PROCEDURE OF GENERATOR STATOR P-T3109-RED-005
(TURBINE HOUSE) ISSUED DATE :
27 Nov 2008

UNIT ISSUING : APPROVED BY : PAGE REVISION

RED Site Manager 2 of 26 2

ORIGINATED BY REVIEWED BY APPROVED BY DISTRIBUTION

- SDCC : Original
- CNEEC : Copy
- Originator: Copy

Budianto Rusli Joko Purnomo Iman paryaman Agus Subagyo

Rigging Engineer Area Manager Site Manag. Rep Site Manager

ISSUED EFFECTIVE
REV. NO BRIEF OF REVISION
DATE DATE
0 22-10- 2008 22-10- 2008 CHANGE TEMPORARY BEAM AND SPREADER BEAM
1 14-11- 2008 15-11- 2008 REVISION AS COMMENTS
2 27-11- 2008 28-11- 2008 ISSUED FOR APPROVAL

TABLE OF CONTENT

No. Descriptions Page

1 Title 1 of 26

2 Scope 3 of 26

3 Objective 3 of 26

4 Reference 3 of 26
5 Description Procedure 3 of 26

5.1 Equipments Specification and Rigging Tools 3 of 26

5.2 Execution 4 of 26

5.2.1 Installation of Equipment 4 of 26

5.2.2 Lifting Generator Stator 5 of 26

6 Risk analysis 6 of 26

7 Attachment 7 of 26
 DOCUMENT NO. :
LIFTING PROCEDURE OF GENERATOR STATOR P-T3109-RED-005
(TURBINE HOUSE) ISSUED DATE :
27 Nov 2008

UNIT ISSUING : APPROVED BY : PAGE REVISION

RED Site Manager 3 of 26 2

7.1. L 180 Strand Jack 8 of 26

7.2. Power pack L4/15 E 9 of 26

7.3. Fixed anchor housing assembly 10 of 26

7.4. Link Plate Design 11 of 26

7.5. Transport Generator to turbine house building 12 of 26

7.6. Lifting Generator by Jack up system 13 of 26

7.7. Wire sling arrangement 14 of 26

7.8. Detail of Temporary Beam and Spreader Beam 15 of 26

7.9. Calculation for Temporary Beam and Spreader Beam 17 of 26

7.10. Certificate 21 of 26

1. TITLE
LIFTING PROCEDURE OF GENERATOR STATOR

2. SCOPE
This procedure describes the guidelines and operation step for lifting generator
stator by Jack up system.
The Generator Stator has a shipping weight (approximately) 180 tones and size
of 7690 mm (L) x 3800 mm (W) x 4085 mm (H).

3. OBJECTIVE

This procedure is prepared in order to achieve the target of generator stator

lifting at turbine house #1 in middle of December 2008.

4. REFERENCE
1. W – HSE – 001 – Project HSE Management System Plan.
2. W – SAF – 026 Crane & Lifting Procedure.
3. Handbook of Rigging by W.E Rossnagel, P.E (Third Edition).
4. General Catalog, The Crosby group, Inc. ( 2002 Catalog Browser ).
5. Drawing, No : 0EG.340.223S ( Generator Stator )
 DOCUMENT NO. :
LIFTING PROCEDURE OF GENERATOR STATOR P-T3109-RED-005
(TURBINE HOUSE) ISSUED DATE :
27 Nov 2008

UNIT ISSUING : APPROVED BY : PAGE REVISION

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5. DESCRIPTION PROCEDURE

5.1. Equipment Specification and Rigging Tools

1. Strand Jack L 180 Lifting (2 Numbers)

Safe Working Loads : Each SWL 135 Tones Using 9 Dyform Strand.
each strand taking 15 tonnes

Stroke : 500 mm

Lifting Cable System : Each used 9 strand Ø18 mm @ 30 meter long

and minimum breaking loads is 38 tonnes.

Lifting Cable Diameter : 165 mm

Maximum Working Pressure : 350 Bar

Maximum Test Pressure : 420 Bar
Cable Ultimate Strength : 464 Tonnes

Lifting Rate : 12 m/hr

Power Pack : L4/15 E
Supply : 3 phase, 380 - 410 V, 100 Amp.

2. Bridge over head crane include roller /wheel 2 unit (Tandem).

Capacity : @ 80 ton ( 2 units )

3. Wire Sling , Dia 3” x 14M ( 2 EA )

4. Spreader Beam SWL : 200 ton

5.2. EXECUTION

5.2.1. Installation of Equipment.

The actual equipment installation method at site is by winch Cap. 5

tones available at site. The following is proposed :

a) Location of the jack lifting system control panel (power pack)

on the elevation 12m floor (Please, see drawing).
 DOCUMENT NO. :
LIFTING PROCEDURE OF GENERATOR STATOR P-T3109-RED-005
(TURBINE HOUSE) ISSUED DATE :
27 Nov 2008

UNIT ISSUING : APPROVED BY : PAGE REVISION

RED Site Manager 5 of 26 2

b) The lifting strands will be delivered to site in coils and will be

cut to length using disc cutter. The end of strands will be
prepared for threading.

c) The jack base will be tack welded to the jack supports beams
together with the moving bridge and the fixed anchor blocks
installed inside their fabrications.

d) The jacks and fixed anchor will now be threaded with their
strands comprising the lifting cables.

e) The complete assemblies of jacks, beams, cables, anchors

and fabrications will now be lifted in to place and secured.

f) Connect the power supply ( 3 phase, 380~410V, 100Amp) to

power pack.

g) Connect the hydraulic hoses from the power pack to the

jacks. The equipment will be given a full function test prior to
commencement of the lifting operation. On completion of
testing, the power pack relief valves should be set and locked
off at 10% above expected load.

h) Erect a temporary platform below the jacks to facilitate

threading of strand cable.

i) Hoist strand cable 1 piece at a time by means of a winch. One

end of the stand cable is threaded through the jack and the
other end terminated in fixed anchor block housed in spreader
beam.

j) Once all the required numbers of strand cables are threaded,

each strand is nominally pre-tensioned to eliminate
overloading any one single strand initial lift-off.

5.2.2. Lifting Generator Stator

A. Preparation works
Access way from Generator Storage to inside Turbine Building
house axis 9-10 shall be cleared and compacted wherever required
for the transportation of Generator Stator by Goldhover Trailer.
All rigging tools such as Sling, Shackle, spreader beam and strands
of Over Head Crane ensure that in good condition. On 0 meter
ground located on open space of T/G house, marking by paint the
longitudinal and horizontal centerline, led from generator’s
foundation for unloading generator stator position.
 DOCUMENT NO. :
LIFTING PROCEDURE OF GENERATOR STATOR P-T3109-RED-005
(TURBINE HOUSE) ISSUED DATE :
27 Nov 2008

UNIT ISSUING : APPROVED BY : PAGE REVISION

RED Site Manager 6 of 26 2

B. Rolling off of Generator Stator on Goldhover Trailer.

Goldhover trailer inside Turbine House axis 9-10, after
goldhover trailer pass column A axis 9- 10, then turn to north side
so that it’s center coincide with center of axis 9-10A(see
attachment).
Generator Stator on goldhover trailer shall be positioned and
then rolled off after carrying the Generator Stator into the Turbine
Building unloading bay under Over Head Crane.
Upon confirming the lifting position of Generator Stator, lifting
strands connected to the spreader beam shall be connected to the
Generator Stator for lifting as per drawing attachment

C. Lifting & Positioning of Generator stator

Install spreader beam and rigging tools (sling) . By the use of
two Strand Jack on the over head bridge Crane, Generator Stator
shall be lifted up and mounted to EL 12000, then two Over Head
Crane together carrying Generator Stator shall be moved towards
the final position / foundation. Two units of overhead crane will be
performed parallel operation by using manufacturer’s conjunction
devices. And the center distance between the cranes should be
confirmed to be 8095 mm, while control cables of the travel
mechanism should be connected so as to ensure that the travel
mechanism of two cranes can be controlled by one crane.
Upon reaching the final position, Generator Stator shall be
lowered gradually and placed in position on base support.
Centering and final alignment work shall be continued.

6. Risk Analysis :

1. Check Jack L 180 condition before lifting.

2. Check rigging tools & accessories condition such as strand/wire rope,
spreader beam, shackle & wire sling shall be checked firmly in advance and
confirmed thoroughly that no any defective point exist.
3. No activity to be allowed in and around lifting area during lifting activity.
Install barricade tape to secure the lifting area.
4. When the stator is initially lifted 100 mm over the ground by hydraulic jack
system, and remains stationary for 10 minutes, lifting system should be
checked and confirmed to be no problem and then trial braking is performed.
Only after the above is confirmed to be in a good condition then the stator
can be lifted formally.
5. For reducing the braking inertia, brake of the travel mechanism can be
loosened appropriately. The value of over current protection for travel
 DOCUMENT NO. :
LIFTING PROCEDURE OF GENERATOR STATOR P-T3109-RED-005
(TURBINE HOUSE) ISSUED DATE :
27 Nov 2008

UNIT ISSUING : APPROVED BY : PAGE REVISION

RED Site Manager 7 of 26 2

mechanism motor should be adjusted highly, so as to avoid over current and

power breaking during the travel for two cranes.
6. In lifting process of hydraulic jack system, speed difference of temporary
spreader beam should be paid more attention to at all time. Punctual
adjustment is necessary for maintaining the lifting material level.
7. Operational handle of control panel and hydraulic jack should be numbered
respectively, and each number should be corresponding to its unique handle.
8. During the lifting the power pack, operator will monitor the individual jack
loads. In addition, the operator will need to be in contact with the lift
coordinators and spotters watching the generator clearance and level.
9. Workmen wear proper PPE (Helmet, safety shoes, full body hardness/
Safety belt, etc) and lanyard hook of body harness always hooked up while
working at height.
10. Manning scheme for lifting of generator shall prepared after reviewing
thoroughly by personnel relevant to the works, and the procedure shall be
carried out under careful verification

7. ATTACHMENT

7.1. L 180 Strand Jack

7.2. Power pack L4/15 E
7.3. Fixed anchor housing assembly
7.4. Link Plate Design
7.5. Transport Generator to turbine house building
7.6. Lifting generator by jack up system
7.7. Wire sling arrangement
7.8. Detail of temporary beam and spreader beam
7.9. Calculation for temporary beam and spreader beam
7.10. Certificate
 DOCUMENT NO. :
LIFTING PROCEDURE OF GENERATOR STATOR P-T3109-RED-005
(TURBINE HOUSE) ISSUED DATE :
27 Nov 2008

UNIT ISSUING : APPROVED BY : PAGE REVISION

RED Site Manager 8 of 26 2