AL.SK CRANES AL.SK190 & AL.SK350

2

Smarter

Safer

Stronger

At the heart of ALE’s business are our people: dedicated professionals who work with our clients to achieve the very best results. We employ imaginative people at all levels within the company, who focus on developing innovative solutions for the most complex projects. We challenge conventional thinking, aspire beyond accepted limitations, and don’t stop until we have the smartest, most effective solution to each and every challenge. Our Innovation Series is just one example of our insistence on pushing the boundaries to create solutions that work best for our clients.

ALE is a responsible business with a strong moral core, so the safety and well-being of the individuals we work with and the clients we work for is our single most important consideration. Minimising risk to our staff, our clients and members of the local community is a priority at the highest level of the company, and an ethos that permeates every aspect of our business.

We haven’t become one of the world’s foremost experts in heavy transportation and lifting by thinking small. By investing in the latest technologies and employing the best people in the business, we’ve grown over more than 30 years into a global leader with a presence across a breadth of sectors and markets. Our flexible approach suits any project, whatever its size or scale, and our clients know they can rely on us for commitment, innovation, delivery, service and an agile, proactive approach that gets results.

Together, we are...

3

4

CONTENTS OVERVIEW ALE has always been distinguished by its engineering capabilities. We’re recognised as a world leader in equipment and solution development, and from the opening of our Research and Development facility in Breda, the Netherlands, our innovative product design has dominated industry news and redefined the boundaries of heavylifting capability in a global market.

In the last few years, ALE’s R&D facility has been responsible for numerous achievements in product development that include the world’s largest capacity land based cranes, the AL.SK cranes.

3 Overview

4 Design

5 AL.SK190, AL.SK350

6 DESIGN ADVANTAGES

7 Small Plot Area & Reduced Onsite Disruption

8 High Capacity & High Speed Lifting

9 Variable Ballast Radius

10 More Accurate Scheduling for Shipyard Applications

11 Boom ‘Failsafe’ Topping System

12 Simplified Logistics & Assembly

13 OPERATIONAL ADVANTAGES

13 Assembly

15 Even Ground Load Distribution & Faster Onsite Relocation

16 Ballast

17 Tailing Crane Location

19 Grounding Bearing Pressures & Ground Settlement

21 Slewing Operation & Boom Erection

23 Operating Wind Speeds & Control Systems

24 Steering Winches

26 Safety Features, The Future & Engineering

28 ‘CASE STUDIES’

28 NGL4, Ruwais

29 Valero Coker Interchange, Port Arthur

30 RRE2, Ruwais

31 Thai Growth, Thailand

32 MFC Project, Sadara

33 LPG4, Kuwait

5

DESIGN

ALE first conceived the idea of a new heavylift land based crane in 2006 when it became clear that there was a requirement in the market for increased lifting capacity. Our clients were looking to lift increasingly heavy items at larger radii while reducing costs and construction time and maintaining safety.

With over 30 years in the business, ALE has forged close relationships with leading EPC contractors, fabrication yards and shipyards and we were able to use these connections to gather as much information about the future needs of the heavy lift industry as possible.

After close consultation with a number of interested parties, we defined our objectives for the project as follows:

In addition to these high level objectives, R&D’s designs focused on a number of innovations which would ensure that the AL.SK was not simply a new crane, but a new type of crane altogether. For example, by developing a solution that enables the AL.SK to rotate around the ballast, the designers were able to provide a high capacity and improve outreach. Unique honeycomb mats that distribute load laterally and longitudinally with flexible connections rather than a fixed ring meant that the AL.SK could operate without a full ring of crane track. This design also allows for settlement of the ground under the crane, as the crane is hydraulically self levelling to maintain the verticality of the boom. And the use of both strand jacks and winches would create a combination of lifting options for maximum flexibility currently up to 5,000t capacity. ALE’s R&D team were also keen to ensure that the AL.SK would de-rig for easy transportation in ISO 20ft and 40ft shipping containers, and of course, that it was designed to the latest and most stringent global safety standards.

After a rigorous programme of testing, the AL.SK190 was launched in 2008 as the world’s largest capacity land based crane. Its enormous success and popularity led to a second being built and launched in 2011.

A new design of crane with the highest capacity in the market

That the crane could be configured differently in size to suit the lift and site limitations whilst using the space efficiently

To ensure the speed and efficiency of smaller lifts

To enhance safety, accuracy and performance

AL.SK190

The AL.SK190 – named to reflect the measurement of the load moment based around the point of rotation, which is the standard industry convention for measuring the lifting radius of cranes – has a lifting capacity of 4,300t, a maximum boom height of almost 200m, and a load moment of 196,000tm. It has two big advantages: it can perform lifts previously unachievable, and it can do this while occupying a very small footprint of just 35m x 55m.

AL.SK350

Due to the global demand for AL.SK cranes and the requirement for even greater capacity the AL.SK350, launched in 2013, has now taken its place as the largest capacity land based crane in the world by some distance. With a lifting capacity of 5,000t and a load moment of 354,000tm, this crane will enable the development of new and groundbreaking construction methodologies and save our clients time and money on the construction site by reducing schedule, risk and cost.

7

To be able to lift and install a 120m high column weighing 3,000t

SMALL PLOT AREAThe AL.SK’s central ballast design eliminates the need to install a full ring or crane track. Instead, ALE only needs to install the section required for the project – as little as 45 degrees – creating valuable onsite access routes for plant personnel and vehicles. This also means the occupancy of the lifting area can be reduced by up to 45%.

DESIGN ADVANTAGES

9

REDUCED ONSITE DISRUPTION

The large lifting radius of the AL.SK’s means the cranes can be fully rigged and operated off-plot, with fewer lifting positions, resulting in less ground preparation work. This allows normal operations to continue onsite while critical pieces are installed, minimising disruption and saving clients schedule time and costs.

Due to their enhanced design, the AL.SK’s are capable of working at higher wind speeds compared to crawler cranes or ring cranes resulting in significantly less down time onsite.

DESIGN ADVANTAGES

10

HIGH CAPACITY & HIGH SPEED LIFTINGThe unique combination of winches up to 4,000t lifting capacity (including the option for a 600t quick winch for smaller lifts) and strand jacks up to 5,000t lifting capacity means both small and ultra-heavy items can be lifted efficiently.

VARIABLE BALLAST RADIUS

Due to the unique design of the ballast being central to the cranes’ rotation, our engineering team can vary the ballast radius to suite the lift and site conditions. This can offer benefits of increasing lift capacity by 100% or reducing the crane footprint by 75%. It also increases the outreach exponentially compared to fixed ring cranes.

11

DESIGN ADVANTAGES

12

DESIGN ADVANTAGES

BOOM ‘FAILSAFE’ TOPPING SYSTEMThe Boom Topping System comprises of a hydraulically operated chain clamping system that is mechanically locked during operation as an additional safety system.

SIMPLIFIED LOGISTICS & ASSEMBLY

The mobilisation and assembly period is kept to a minimum thanks to the containerised design and fast-assembly features such as hydraulic pins and couplings. This means our specialised team can assemble the crane in only four weeks and using crawler cranes with a maximum capacity of 400t.

13

14

ASSEMBLYThe AL.SK crane features unique hydraulic pin connections. These improve safety and save time when assembling the crane. Furthermore, this design reduces the wear of pins during service, again enhancing safety and reliability.

OPERATIONAL ADVANTAGES

15

OPERATIONAL ADVANTAGES EVEN GROUND

LOAD DISTRIBUTION

The unique honeycomb design of the load spreading mats means that the load is evenly distributed over the whole area of the mat surface.

GROUNDING BEARING PRESSURESUtilising specialist load-spreading and hydraulic systems beneath the AL.SK crane, ground bearing pressures are kept to a minimum. For AL.SK350, maximum ground bearing pressures are 20.4t/m2 beneath the 4,000t ballast system.

The average ground bearing pressure beneath mast foot during medium range use is around 25t/m2. The actual ground bearing pressures are dependent upon load case and configuration.

OPERATIONAL ADVANTAGES

BALLAST

AL.SK cranes utilise locally available ballast material. This is intended to be readily available material depending upon location, for example sand, gravel or other suitable weights or mass.

Special reinforced 40’ open-topped containers are used for the ballast material, filled by standard mechanical shovel. Weight of each filled container is 100t, requiring around 4,000t of local ballast (2,800m³ sand).

17

OPERATIONAL ADVANTAGES

TAILING CRANE LOCATIONDue to the high capacity of the AL.SK cranes, it is usually feasible to lift a large petrochemical column with the column head fiurthermost from the AL.SK crane and to boom back during tailing to the vertical.

This means that the tailing crane can be located close to the boom foot/base of the AL.SK, which avoids the tailing crane being positioned ‘on plot’ or in a location that may require additional ground preparation.

STEERING WINCHES

Steering winches, which are fitted to the backmast, can be used to prevent the load rotating on the hook during lifting operations and avoids the use of tag lines.

Steering winch

19

21

Hydraulic Cylinder

OPERATIONAL ADVANTAGES

FASTER ONSITE RELOCATION

The AL.SK’s can be relocated onsite using either by skidding using existing crane track or SPMTs. This means the most suitable method can be chosen depending on the individual characteristics of each project site, and the time and cost implications of de-rigging, relocating and re-rigging the crane can be considered and minimised.

GROUND SETTLEMENT

A hydraulic cylinder is positioned in each skid shoe which can compensate up to 400mm in stroke, having the crane structure supported on hydraulic cylinders allows our engineers to calculate the exact ground-bearing load underneath the crane at any position, any time during the project. In the event that settlement takes place it can jack-up the foot of the mast to keep the crane structure level to reduce any side loadings which can occur on un-level ground; The pressure readings in the hydraulic cylinders are also used to monitor the loads in the mast foot and is used as an extra safety feature.

22

OPERATIONAL ADVANTAGES

BOOM ERECTION

During assembly, the main boom is lifted and erected by the main topping system and back mast, thus avoiding the use of a large support crane for this operation.

23

SLEWING OPERATION

AL.SK cranes are capable of slewing up to 28m per hour under load and up to 50m per hour without load utilising a special design of gripper units. They also operate as safety stop when ground settlement or high wind forces occur. They can lock the crane in position or be used to slew the crane back to a safe position.

Wind Speed Beaufort m/s Km/hr

Operational 7 14.4 52

Design 8 20 72

Survival 12 67 241

OPERATIONAL ADVANTAGES

OPERATING WIND SPEEDSThe design of the AL.SK crane allows for operational wind speeds at 20m/s. A typical large crawler crane has an operational wind speed of circa 9m/s with a boom over 80 metres. This means the AL.SK crane could have 60% less downtime than a large crawler crane in a high wind environment, thereby maintaining schedule and reducing cost risk.

CONTROL SYSTEMS

The AL.SK control systems use the Siemens Programmable Logic Controllers (PLC) software, which enables remote access for analysing, upgrading and problem solving. This can avoid downtime with real time access offsite.

25

2726

MORE ACCURATE SCHEDULING FOR SHIPYARD APPLICATIONSA combination of increased capacity and radius means that the crane can be used as an alternative to floating cranes and crane barges for lifting modules directly from quay/barge to vessel hulls. This minimises the offshore installation process and allows for more accurate scheduling that doesn’t depend on weather and tidal conditions.

OPERATIONAL ADVANTAGES

WIDER REACH FOR HIGH CAPACITY LIFTS

With a wider radius, the AL.SK cranes can lift up to 1000t with a 300m rotation, providing extended reach to areas inaccessible to crawler cranes. Due to this extended reach, clients can achieve significant reductions in equipment on site, ground space required and project schedules.

28

SAFETY FEATURES, THE FUTURE & ENGINEERING

SAFETY FEATURES

The AL.SK cranes have been designed in accordance with the most stringent safety regulations: the European DIN and EN standards and the America AWS codes. In order to achieve accreditation, every stage was checked, witnessed and approved by globally recognised independent surveyors. Using these strict criteria ensures the very highest standards of design and fabrication.

BACK UP OPERATING SYSTEMSAL.SK cranes are critical pieces of machinery and so ALE engineers have built in primary and secondary/emergency backup systems for crucial elements such as powerpacks, generators and pumps.

THE FUTUREALE’s R&D facility continues to focus on improving current equipment and creating new solutions for the industry. Having a dedicated development facility gives our highly skilled engineers a platform from which to

push the boundaries of design. With this expertise and a close working relationship with our clients, we have a full understanding of the market and develop our equipment to suit demands for now and the future. ALE is committed to being proactive to the needs of the industry: our foundations have not been built on being an equipment rental only company, we actively develop solutions to challenges faced by clients and solve them through innovation.

The AL.SK crane fleet is also being extended – although our current cranes are the largest capacity to have been developed since 2008, our commitment to continuous improvement means our R&D department is already working on the AL.SK500. This 8,000t capacity crane – in combination with our 60,000t capacity Mega Jack system – will break further records in the industry, and allow the world’s leading offshore fabricators to rethink their construction methods and develop their own innovations. In this way, ALE is sparking improvements across many sectors all over the world.

SAFETY FEATURES, THE FUTURE & ENGINEERING

ENGINEERING & FEED SUPPORT Our experience and pedigree in innovative engineering means we’re well equipped to support the full process of project development including early engineering and FEED. ALE has contributed to many high profile projects at the forefront of technological innovation. We’re able to adapt – both in the long term to the industry’s ever-changing requirements and safety standards and in the short term as the scope of each project becomes more defined. We work closely with our clients from the very earliest stages to establish exactly what’s required and provide engineering advice, because working through complex technical and logistical issues at the beginning helps to eliminate expensive changes later on.

29

3030

CASE STUDIES

ALE successfully demonstrated the key benefits of an extended lifting radius with a series of record-breaking lifts at an oil refinery in Port Arthur, Texas, USA. Using its AL.SK190 heavy lifting machine – the first use of this award-winning crane in North America – ALE completed a two stage project that involved lifting 1,338t at 54m outreach.

In the initial phase of the project, the AL.SK190 was used to exchange coker drums, removing 6 old drums and replacing with 6 new drums weighing up to 471t each. The crane first lifted a 1,400t derrick structure, which was positioned on top of the existing coker drums at a height of 100m, and set it on the ground. The coker drums were then exchanged, and the derrick structure replaced.

The derrick lift performed by the AL.SK190 was the first time a complete derrick assembly consisting of triple drill towers and cutting deck, had been removed and replaced in a single piece.

The lift required a complex tackle arrangement with a twelve point pick up only possible with the AL.SK190 crane. To successfully complete the project without the need to shut down the coker the AL.SK190 was rigged outside the boundaries of the coker pit. This also enabled the completion of the project with no permanent equipment in the refinery having to be dismantled, and the coke pit wall did not have to be removed.

In addition to the AL.SK190, ALE utilised an 850t tailing gantry and sixty axle lines of SPMT to complete the HCU installation. ALE also supplied all of the engineering calculations and related support.

The 4,300t-capacity AL.SK190, which won the Innovation and Development Award for End Users at the 2010 ESTA Awards of Excellence, has a load moment of 190,000tm, a 141m main boom and a 32.1m ballast radius, and also features a 600t quick winch system for lifting smaller items quickly.

CASE STUDY CASE STUDYNGL4, Ruwais, UAE

Transportation and erection of seventy heavy lifts including a deethaniser column weighing 1,425t, and a depropaniser column weighing 1,401t, into a gas plant as part of an expansion project in Ruwais to incorporate a 4th NGL train.

ALE received the pieces from heavy lift vessels and ocean barges at Mina Zayed port in Abu Dhabi onto conventional trailers and SPMTs. ALE jacked the two main columns up 2m from 1.5 to 3.5m to allow bolsters to be positioned underneath.

All items were transported across the port and loaded-out onto the ALE250 and ALE300 barges.

During this phase ALE completed the ballasting for each barge and the sea fastenings through detailed engineering analysis.

In a total of eleven voyages all cargo was barged to the Ruwais Industrial Area Harbour where the ro-ro operation was completed. The two mile route to site required the 71metre long columns to negotiate several tight junctions along route with live facilities either side.

Using ALE’s 3,000t bolsters during the transportation of the main columns enabled potential disruption, modifications to the road network,

and street furniture removal to be kept to a minimum. Without the bolsters major infrastructure modifications would have been required at considerable cost, and disruption to neighbouring facilities.

These bolsters were specifically designed by ALE to transport the weights that the AL.SK190 was designed to lift.

Once the pieces were on site, the AL.SK190 tailed by the 1,600t capacity CC8800-1 completed the lifts to install the two main columns. The CC8800-1 crane was used to lift and install the items weighing between 250 – 500t, and the 600t capacity CC2800-1 cranes were used to lift and install all items weighing less than 250t.

The main advantage to using the AL.SK190 on this project was that the cranes radius allowed the 1,400t columns to be lifted onto their foundations from one fixed position; this particular project required a 77metre outreach to complete the installations. Another advantage to using the AL.SK190 was the footprint of the crane. The base of the crane can be adapted to use only what is required to complete the lifts for that project, this therefore minimises the space required and allows other construction works in the lift area to proceed unaffected by the lift sterilisation areas.

Valero Coker Interchange, Port Arthur, USA

31

32

ALE completed a series of lifts as part of the Thai Growth Project in Map Ta Phut, Thailand. With weights ranging from 73t up to 813t, twenty-five items were transported, lifted and installed in just twenty-two days.

The Thai Growth Project originally specified a large crawler crane from three positions, with the lifts taking place over a three-month period. However, the AL.SK190’s record-breaking capabilities reduced this to less than one month, achieving significant cost and schedule savings for the client.

Due to its high outreach capacity, the AL.SK190 was able to perform all required lifts from a single location, avoiding the expense and time associated with de-rigging, re-rigging and re-locating. Columns could be lifted over the new structure, enabling other structures and pipe racks to be installed ahead of schedule. The AL.SK190 also required minimal ground preparation for the 25t/m2 loading under the mast foot and 20t/m2 under the ballast.

The twenty-five items lifted as part of the project weighed a combined 4,230t.

Key installations included:

• A 85m x 8ø column with a total lift weight of 850t and an installation radius of 114.4m

• A 75m x 8ø column with a total lift weight of around 700t, which had an installation radius of 70.6m

• 50m x 6ø column with a total lift weight of 250t and an installation radius of 110m

The project also made use of the AL.SK190’s unique Quick Winch system. Depending on reeving, the block speed goes up to 750m per hour. The winches are equipped with 2500m of cable each, which means the fully reeved hook block can reach the ground with mast lengths of up to 200m.

CASE STUDY

ALE’s AL.SK190 was required on site at a project within the Ruwais area, UAE, at a refinery expansion project for a new build residual fluidised catalytic cracker unit (RFCC).

This project saw a total of ninety-two lifts, including seven in four separate locations with the AL.SK190. During these lifts the 1,600t capacity CC8800-1 was used as the tailing crane for the AL.SK190. The first of the seven pieces included an 1,100t reactor, a 1,200t main fractionator column, and a 1,900t regenerator.

In addition to serving as the tailing crane the CC8800-1 crane also completed sixteen lifts independently.

RRE2, Ruwais, UAE

CASE STUDYThai Growth, Map Ta Phut, Thailand

33

CASE STUDIES

CASE STUDY

ALE completed one hundred & sixty-one installations at a chemical plant in the Eastern province of Saudi Arabia.

To complete the installations which were to the Mixed Feeder Cracker (MFC) ALE utilised the AL.SK190, the LR1800 - 800t capacity - as a tailing crane, and the CC2800-1 600t capacity crane. The pieces installed ranged from 25 – 1,329t.

MFC Project, Sadara, KSA

Transportation and Installation of De-ethaniser tower weighing 1,315t was completed at a refinery in Kuwait.

Planning for the installation of the tower began almost a year prior to the operation. The transportation presented the biggest challenge with route surveys and route modifications required the tower was then transported by SPMTs. On site the lift and installation by the AL.SK190 crane took twelve hours to complete. ALE was selected to complete the lift because of the AL.SK’s ability to independently install the structure.

CASE STUDYLPG4, Kuwait City, Kuwait

35

CASE STUDIES

36

EUROPEUnited Kingdom Staffordshire, Head Office +44 (0) 1889 272 500

United Kingdom Middlesbrough +44 (0) 1642 292 299

The Netherlands +31 (0) 76 571 5240

Spain +34 91 884 54 03

Germany +49 (0) 211 9754889

Russia +7 499 917 07 02

Norway +47 95 73 69 25

Belgium +31 76 571 52 40

France +33 60 359 6585

Poland +48 58 342 25 34

NORTH AMERICA & CANADA

USA +1 (0) 713 946 3125

Canada +1 780 701 9595

Mexico +52 (833) 262 01 93

SOUTH AMERICABrazil +55 (21) 2233 8489

Argentina +54 (11) 4545 9315

Venezuela +58 (0) 212 2632 576

Colombia +57 1 610 92 34

Panama +507 6704 9608

Peru +511 440 0723

AFRICANorth Africa +34 91 884 54 03

South Africa – Cape Town +27 (0) 21 842 2762

South Africa – Johannesburg +27 (0) 11 453 1946

MIDDLE EASTIraq +964 7817 655 833

United Arab Emirates +971 2 550 8741

Qatar +974 4456 7730

Kingdom of Saudi Arabia +966 (0) 3 3448551

Azerbaijan +994 55 20 344 20

ASIA PACIFICIndonesia +62 21 31907912

Malaysia +60 7 2553 202

Thailand +66 38 893 700

Korea +82 (0) 2 2040 7785

Vietnam +84 64 359 7771

Australia - Brisbane +61 (0) 7333 9 1310

Australia - Perth +61 (0) 8614 4 4410

QR CODE

WORLDWIDE HEAVY TRANSPORTATION AND LIFTING