New Generation PTC Super heavy lift cranes
The “smallest” super heavy lift cranes
Mammoet’s New Generation PTC cranes - key features page
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1. Designed and built to the highest international safety standards, verified by Lloyd’s Register
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2. Nonstop load chart interpolation: flexibility and time savings
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3. Luffing jib reaches across plant structures, without reduction of the load moment
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4. Wheeled bogies: slew a full circle in 15 minutes
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5. Fast winches lift loads up to 3,200 t (3527 US ton) to 120 m (394 ft) from 12 minutes
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6. Winches, not strand jacks, so no need for frequent hoist rope replacement
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7. Smallest footprint heavy lift crane: swing radius, including ballast, only 22 m (72 ft)
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8. Low ground bearing pressure: max. 20 t/m² (4100 psf) across a diameter of 45 m (148 ft)
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9. High reliability: electric and hydraulic systems 100% redundant and the experience of 17,000 PTC lifts
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10. Operational wind speed 14 m/s (31 MPH), design wind speed 18.5 m/s (41 MPH), survival mode 67 m/s (150 MPH)
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11. For all climates: artic-proof down to -40°C (-40°F), desert-proof up to +55°C (+131°F) - no load chart reduction
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12. Containerized: worldwide mobilization in 3 to 6 weeks
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13. Relocation on site on SPMTs or on crane track
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14. Reduced environmental impact: “green ballast” and reduced emissions
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Mammoet’s New Generation PTC cranes: Versatile and efficient super heavy lift cranes with a small footprint
PTC: Platform Twinring, Containerized Mammoet has a worldwide fleet of some 1300 cranes. However, conventional cranes are simply not enough for our largest projects. In 1996 we designed and built our first PTC. The crane platform rests on a ring for slewing, the twin booms form a stable A-frame, and all the components are the size of standard shipping containers. These PTCs allowed us to undertake large projects more efficiently, even at remote sites. Mammoet now has more than ten of these cranes and a wealth of experience developed over 17,000 heavy lifts with them. We also have 15 years’ of in-house expertise of engineering these super heavy lift cranes. The success on the market proved the validity of the concept and we have developed it into the New Generation PTC cranes described in-depth in this brochure. We are building three of these cranes, in two sizes, and already have several launch customers designing projects around them.
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15 years of in-house engineering
MSG
T30
1996
Gantry: Strandjacks
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PT50
PTC35
PTC35 DS
2000
Sliding Bogies
Winches
New Generation PTC
2011
Wheel Bogies
Cranes and sliding gantries compared The PTCs are real cranes, not sliding gantries (or lifting machines). Sliding gantries operate more slowly, move on skid shoes, and use strand jacks for lifting. This is a suitable concept for a single heavy lift during a project, for example using Mammoet’s MSG system. However, a PTC crane is far more versatile and efďŹ cient and can be used for many lifts during a project. Furthermore, the strand wire used with strand jack systems suffer heavy wear and need to be replaced after a few lifts, which is costly and takes time.
Single lift versus multi lifts PTC (multi lifts)
MSG (single lift)
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MSG (single lift)
Mammoet PTC (multi lifts)
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1. Designed and built to the highest international safety standards The New Generation PTCs are designed to meet both European and American safety standards (EN 13000, ISO 4305, ASME B30.5, SAE J987, ASME NQA-1). The design and construction are fully certified by Lloyd’s Register (design approval, fabrication survey, test witnessing). This included a full and detailed design review. One of the key design requirements was to ensure the safety of the riggers when erecting the crane. This has been done by providing safe walkways and other fall-protection measures. Hence, the high safety standards you maintain will be complied with throughout Mammoet’s presence on your plant. These PTCs feature unique hydraulic pin connections designed in-house by Mammoet. These improve safety and save time when erecting the crane. Furthermore, this design reduces the wear of the pins, again enhancing safety and reliability.
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2. Nonstop interpolation There are three options for rigging the New Generation cranes : - main boom (SSL) - main boom + fixed jib (SFSL) - fixed main boom + luffing jib (SWSL) These modes make the cranes even more versatile when striking the balance between maximum load and maximum radius, and give a greater choice when determining their location on site. For operation in SWSL mode, load charts are provided for selected main boom angles. For greater flexibility, interpolation between two load charts possible. This is Mammoet’s unique “nonstop interpolation” principle on a ringer crane. This means that any lift can be planned to make the best use of the crane capacity. The load charts for the SSL and SFSL modes specify the maximum loads at specific radii. The maximum load at an intermediate radius may be obtained by interpolation within a load chart.
Variable Angle
235m (770 ft)
Non-stop interpolation
205m (672 ft)
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GBP = 20 t/m2 (4100 psf)
3. Luffing jib to reach across plant structures The New Generation PTCs are generally fitted with a luffing jib [length: 42 m (138 ft) – 106 m (348 ft)] to lift loads across structures on your plant. The luffing jib also makes it possible to position the crane such that a more favorable load moment is obtained. This is a great advantage over sliding gantries with a rigid main boom, which have to be positioned at a much greater distance from the load to reach over structures. The smaller operating area required by a PTC is another key advantage, especially on congested sites. For a PTC with luffing jib, a load of 1000 t (1100 US ton) at a radius of 100 m (328 ft) is a easy feasable lift. The control software incorporates “virtual walls”, essentially exclusion zones to ensure that the crane only operates in a permitted area, to ensure safe operations.
4. Wheeled bogies for efficient slewing The New Generation PTCs slew on bogies and can rotate a full circle in just 15 minutes. This makes operations much more efficient than with sliding gantries moving on skid shoes. Slewing 360 degrees means that loads can be picked up and placed across a large part of the site, for more efficient lifting operations. The control system suppresses stick-slip at the start of slewing, for smoother operation and greater safety. The slewing drive is powered by redundant hydraulic powerpacks for high reliability.
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5. Fast winches 125 - 250 t up to 20 m/min 138 - 276 US ton up to 66 ft/min
250 - 3200 t 120 m from 12 minutes 276 - 3527 US ton 394 ft from 12 minutes
The cranes are fitted with four 800 t (882 US ton) main winch systems for a total lifting capacity of 3,200 t (3527 US ton). These winches are automatically synchronized and controlled. Loads up to the maximum capacity are hoisted at a speed of 10 meters per minute (33 ft/min). This makes operations much more efficient than with gantries using strand jacks which typically have a lifting speed of 10 meters per hour (33 ft/hr). The New Generation PTCs are also fitted with a 250 t (276 US ton) auxiliary hoist, with a lifting speed of 10 (33 ft/min) or 20 m/min (66 ft/min), depending on the configuration. All lifting operations are monitored by fully redundant load cells in the main boom and luffing jib, and controlled by duplicated PLCs. The electronic systems also feature remote diagnostics for improved efficiency and safety.
6. Winches, not strand jacks
360° 15 minutes
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Although strand jacks are valuable tools for heavy lifting operations, and regularly used by Mammoet, they are best suited to single lift projects. This is because they are slow and wear the strand wire out quickly which then needs replacement. The New Generation PTCs use winches for more efficient operations and a much longer rope life.
7. Small footprint As the New Generation PTCs carry all the ballast within the ring they have zero tail swing. This is a great advantage when operating on congested sites. It also means the crane can be positioned closer to the load to make better use of the available load moment. The swing radius of only 22 meters (72 ft) (including ballast) makes the New Generation PTC cranes the “smallest” super heavy lift cranes.
PTC Footprint diameter 45 m (148 ft)
PTC Footprint diameter 55 m (180 ft)
140,000 tm GBP = 20 t/m2 (4100 psf)
200,000 tm GBP = 20 t/m2 (4100 psf)
8. Low ground bearing pressure The New Generation PTC cranes have load spreaders, with an outside diameter of 45 m (148 ft). This results in a maximum ground bearing pressure (GBP) of 20 t/m². Hence, only limited site preparations will be needed. This is a key advantage over equipment such as heavy crawler cranes which can have a GBP up to 100 t/m² (20500 psf).
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9. High reliability: 100% redundant systems All key electric and hydraulic components of the New Generation PTCs, such as the power packs, gearboxes, slewing and hoisting drives, PLCs and electronics are fully duplicated. Hence, repairs and maintenance can be carried out without interrupting the lifting operations. The hydraulic powerpack is driven by two Caterpillar C18 diesel engines which meet strict emission requirements. If one powerpack fails or needs to be shut down for maintenance, the crane can continue operations at full capacity. In the unlikely event of failure of both powerpacks the crane can be operated using an external powerpack (manual system). The PLCs, load cells on the boom and jib and SLI/LMB safety systems and their cabling are also fully duplicated. In the event of a serious external factor the crane is switched from the master to the back-up systems and will be operational again within ďŹ ve minutes. Should all control systems fail then the crane may be operated manually to lower the load. Each of the main winches is ďŹ tted with six hydromotors but can operate at full capacity with only four. Again this means that lifting operations are not delayed by maintenance or repairs.
Redundancy for Drive:
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200% Redundancy,
Redundancy for Boom-Electric (Loadcell, LMB):
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100% Redundancy and
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200% Redundancy,
Manual system
100% Redundancy
The design of the New Generation PTCs benefits from 15 years’ experience and 17,000 lifts with our previous ring cranes, often in demanding environments. The Mammoet engineering department has analyzed the data gathered during these operations and used it to optimize the PTC design in terms of safety, reliability and efficiency.
Redundancy 200%
Redundancy 100% F.e. Hit by lightning
- Mastersystem 100% - backup system 100% - manual 0%
- Mastersystem 0% - backup system 100% - manual 0%
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Manual Redundancy F.e. Hit by earthquake
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- Mastersystem 0% - backup system 0% - manual 100%
Hurricane Survival Mode F.e. Hit by hurricane
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- Mastersystem 0% - backup system 0% - manual 100%
67 m/s (150 MPH)
Optimal Operation
Operational again: within 5 minutes
Secure load: within 4 hours
Hurrican survival mode: within 4 hours
10. Resist high wind speeds The strong A-frame formed by the twin boom allows operations at wind speeds up to 14 m/s (31 MPH), but until 50 m/s (112 MPH) the mainboom and luffing jib can remain fully erected. The crane can be made Hurricane proof [max. 67 m/s (150 MPH)] within four hours. No auxiliary crane is needed for this, or for return to normal operations.
11. Operate and survive in demanding environments Mammoet has extensive experience operating in extremely hot and cold environments. The New Generation PTCs can operate in arctic environments down to -40°C (-40°F) or in deserts up to +55°C (+131°F) without any impact on the load charts. Many other cranes in the market have to be derated below -20°C (-4°F) because of the brittleness of steel components at low temperatures. The New Generation PTCs is built to even survive moderate earthquakes (exact rating t.b.d.).
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12. Rapid mobilization, worldwide Like all PTCs, the New Generation cranes break down into components the size of a standard 20 or 40 foot shipping container. Consequently they can be shipped worldwide without the need for special equipment at ports or in transit. This is a major advantage when working on remote sites in areas with a poor infrastructure. The lufďŹ ng jib means that a PTC is partly self erecting and needs a relatively small assembly area. Only two mobile cranes are needed, which can be provided by Mammoet or obtained locally. Assembling generally takes three to six weeks.
on crane tracks
using SPMTs
13. Relocation on-site The lufďŹ ng jib and large radius of the New Generation PTCs mean that there will be little need to move them on site. However, they can be relocated without disassembly using SPMTs (Self-Propelled Modular Transporters) or on crane tracks.
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14. Reduced environmental impact Like all large cranes, the New Generation PTCs need a significant amount of ballast. Instead of transporting the ballast from a Mammoet depot, locally sourced material is used to reduce the environmental impact associated with transport. This is Mammoet’s “green ballast” concept. The Caterpillar powerpacks are fuel-efficient and meet strict emission requirements. The power management system can shut one of the duplicated powerpacks down to reduce emissions and fuel consumption.
Market segments Offshore
Module lifting in short time: FPSO, FLNG (PAR, PAU) f.e. Module lifting moving on rail track
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Power
Power: all lifts efďŹ cient in short time from 1 position f.e. 1000t @ 100m radius (1100 US ton @ 328 ft)
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Petrochemical
Safe and less downtime f.e. 2500t @ 65m radius (2756 US ton @ 213 ft) f.e. 3200t @ 55m radius (3527 US ton @ 180 ft)
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combined load charts [metric units] 3500 140,000 tm
3000
200,000 tm
load [t]
2500
2000
1500
1000
500
0 0
25
50
75
100
125
150
175
200
225
radius [m]
combined load charts [US customary units] 4000 140,000 tm
3500
200,000 tm
load [US ton]
3000 2500 2000 1500 1000 500 0 0
100
200
300
400
radius [ft]
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500
600
700
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Mammoet: “Worldwide leader in engineered heavy lifting, transport and project logistics” Mammoet is the world‘s leading provider of turnkey engineered heavy lifting and transport solutions. Our core business is the transport, shipping, installation (including horizontal and vertical positioning) and removal of heavy or large objects, to and from any location, onshore and offshore. Our engineering skills, experience, thousands of highly skilled professionals and a vast fleet of state-of-the-art equipment, combined with high quality and safety standards, have made Mammoet a market leader, setting trends and records around the world.
Markets Petrochemical
Power
Offshore
Fleet
Company
• 1,300 cranes and sliding gantries, 10 – 3,600 t • Jacks, skids and gantries, up to 100,000 t • 3,100 axle lines of Self-Propelled Modular Transporters (SPMTs) and conventional trailers • Sheerlegs, barges and other maritime equipment
• Annual revenues approx. EUR 1 billion • 3,600 employees • In-house engineering department Parent company: SHV • Annual revenues approx. EUR 12 billion • 45,000 employees
Civil
Marine
Safety always a top priority Safety comes first in everything we do. Mammoet operates a stringent, successful and highly respected Safety, Health, Environment and Quality Program (SHE-Q). These standards are always upheld for the safety of all the people and objects involved. The program is implemented throughout our organization, backed up by training and development programs. Our safety officers focus on safety and the impact of our activities on the environment, but it is not their responsibility alone: it is a key responsibility of everyone working at Mammoet. Inventive and innovative Invention and innovation are in our blood, as every assignment is unique. Our in-house engineering department develops specialist solutions and equipment for complex projects. The New Generation PTC cranes covered in this brochure are one example of their work. Worldwide presence Mammoet has 90 offices and operational bases throughout the world to keep lines of communications short. Our advanced logistics operations can deploy equipment quickly, even at remote sites. 25
www.mammoet.com/ptc watch updated news Mammoet’s New Generation PTC Cranes
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Mammoet’s New Generation PTC cranes
Main office: Mammoet Holding B.V. Karel Doormanweg 47, Haven 580 3115 JD Schiedam The Netherlands
The “smallest” super heavy lift cranes
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Tel: +31 (0) 10 2042 424 Fax: +31 (0) 10 2042 442 info@mammoet.com www.mammoet.com
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