The journey from Jack Bore to HDD

Joachim Seyr, LCS Cable Cranes, discusses cable crane systems for constructing pipelines in challenging terrain, including a new Dual Cable Crane System which includes personnel transportation.

Rough terrain, steep mountain ranges and environmentally protected areas often appear impossible to overcome, particularly in the case of pipe installation in this seemingly inaccessible terrain. Innovative solutions can make this terrain manageable, enabling direct routes to be followed, where nobody could have imagined. It is commonplace in the pipeline construction industry that challenging areas must be overcome to complete

the pipeline. When the terrain gets steep, and pipelaying becomes complex and precarious, heavy machinery quickly reaches its limit. With LCS Cable Cranes’ high-tech specialised material handling equipment, such challenges can be mastered.

LCS Cable Cranes, a company based in Austria, has specialised in the construction of pipelines for over 30 years. Various complex pipeline construction projects around the world have been completed by utilising the company’s high-tech cable crane systems. The usage of such systems in steep, rocky and inaccessible terrain allows for transportation along direct routes, as the system can be assembled directly above the planned course of the pipeline. Cable crane systems provide a simple yet efficient solution.

A cable crane system typically consists of one or two fixed track ropes, towers, a hauling rope, a winch and a crane unit. The crane unit moves on the track rope by releasing or alternatively by tightening the hauling rope with the winch installed at the top or valley station. The crane unit can lift the loads and transport them to any position along the pipeline route. It is equipped with its own diesel engine or electric motor and can be easily and safely controlled by the operators by means of remote control. The cable crane system can be configured with various payloads and travel speeds. Advantages of cable crane systems for pipeline construction Flexibility and versatility Cable crane systems are extremely flexible. Professionally planned and thoughtfully designed, they adapt ideally to the environment. Thus, they not only follow the given terrain, but also horizontal bends in the route of the pipeline. The use of high-tech and high-quality machinery and materials allows the system to work independent

of climatic conditions. This significantly extends the operating time – especially if there is need to work during winter months or rainy seasons. Necessary payloads, lengths, terrain, ground conditions, and inclination are just some of the factors that have a significant influence on the best solution. When heavy loads are transported, accurate project management is vital. This includes analysis, planning, installation, implementation, and the operation of the crane systems. However, since the systems are based on a module structure, which allows the development of a consistent and uniquely customised solution, cable cranes are quickly available thanks to their simple installation. Figure 2. Welding works during a project in Greece. The crane unit keeps the pipe in Heavy loads and long distances position. Heavy machinery, construction equipment, pipes, padding material and even manpower can be transported precisely to the designated position. At the loading station, usually at the lowest point in the valley, loads are lifted by a crane unit, then they are pulled by the powerful winch towards their intended position, where they are put down. Loads can be picked up and unloaded at any point along the track with highest accuracy. The cable crane systems of LCS are able to carry loads up to 30 t along distances of more than 3 km and with travel speeds of up to 7 m/s. Environmentally sound and efficient Constructing pipelines in steep and normally inaccessible terrain using cable cranes has a significant positive effect on the environmental impact of a pipeline construction site. Extensive and cost-intensive road building to gain access to the route can be avoided, as all loads are transported in mid-air with cable cranes. Furthermore, it is possible to work in a very narrow channel of approxiately 8 m, which requires less re-instatement costs. These two facts contribute to cost-savings and environmental compatibility. Safe operation in steep terrain Heavy machinery in demanding terrain always involves a risk for operators and the construction site, especially in steep and rocky terrain, where large machinery is pushed to its limits. With the usage of cable crane systems, operators are not exposed to these risks since all material is transported mid-air to its final destination with highest precision. High-tech machinery and equipment is indispensable for the transportation and precise positioning of 20 t heavy loads. All crane systems constructed by LCS follow rigorously the guidelines of the International Organisation for Transportation by rope (OITAF). Additional to the engineering and delivery of a cable crane system, LCS can provide personnel to operate its systems as was carried out for example on the pipeline construction project: ‘Zawtika Onshore Pipeline in Myanmar’.