HaGun Institute

RIGGING PLAN FOR LIFTING

Steam Drum 72 Ton at Boiler
By Winch
PLTU 2X110MW

DOCUMENT NO: Hg-Rig-002

Prepared by

Review by

Approved by

HaGun

Rigging Engineer

SMR

SITE MANAGER

Rev. No.

Effective Date:
04-Apr-2012

Distribution

Master : Rigging

Origin

Copies : CONST. DEPT

BRIEF OF REVISION

: Client

HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
SITE MANAGER

Document No :
Hg-Rig-002

Date :
04/Apr/2012
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TABLE OF CONTENT
TABLE OF CONTENT .......................................................................................................... 2
1.

GENERAL .................................................................................................................. 3

2.

PURPOSE .................................................................................................................. 3

3.

GENERAL NOTE ....................................................................................................... 3

4.

RESPONSIBILITY ...................................................................................................... 4

5.

BASIC REQUIREMENT ............................................................................................. 4

6.

PREPARATION WORK.............................................................................................. 5

7.

ORGANIZATION CHART ........................................................................................... 6

8.

STEAM DRUM ERECTION SEQUENCE ................................................................... 6

9.

LIFTING PROCEDURE OF 72 ton BOILER DRUM .................................................... 8

10.

LIFTING TOOLS ........................................................................................................ 8

11.

RIGGING ANALYSIS ................................................................................................. 9

12.

LIFTING ARRANGEMENT ......................................................................................... 9

13.

WINCH ARRANGEMENT......................................................................................... 17

14.

U BOLT HANGER INSTALLING............................................................................... 19

15.

TEMPORARY HANGER CAPACITIES 50 TON ....................................................... 30

Document No :

HaGun Institute

Hg-Rig-002

Rigging Plan for Lifting

Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
SITE MANAGER

Date :
04/Apr/2012
Pages:
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1. GENERAL
This procedure provides information for the erection of Steam Drum Boiler
2X110MW Project.
2. PURPOSE
This Procedure is to make sure that all people involve in the erection, assembly
and welding of Steam Drum activity understand and familiar to do the work with
quality control system for getting quality result as per client specification and
requirement, drawing, standard and code.
3. GENERAL NOTE
3.1. Inspection
As per the works required inspection, carry out inspection under attendance
of Superintendent / Engineer and as surreally record is result.
3.2. Safety
3.2.1. A safety officer presents all times Safety Briefing.
3.2.2. Job Safety Analysis (JSA) must be carried out for all crane lifts and all
other tasks that have potential risk to personnel of equipment.
3.2.3. Install scaffolding where necessary to install bolt in each beam and
member connection.
3.2.4. Pre lift study before any lifting activity.
3.2.5. Lift briefing and Safety briefing before any lift; assign responsibility to
all personnel involved. (Signalman, Rigger to crane driver, etc.)
3.2.6. Ensure all equipment required for installation is on hand and in
position before lift i.e. Chain blocks, Lever blocks, Podgy, Drifts,
Hammer, and Spanners. Etc.
3.2.7. Tag lines must be used to control lift.
3.2.8. Ground conditions must be ready before activities.
3.2.9. Set up safety rope around lifting area of Steam Drum area and put
notice board entered KEEP OFF EXCEPT PERSONEL
CONCERNED.
3.2.10. Lifting equipment should be in certification and tagged.
3.2.11. Crane and other machinery shall be inspected and certified.
3.3. Lifting
All conditions adapted to the lifting procedure. Prior to commencement of
lifting works, assuredly carry out check of lifting equipment.

HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
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3.4. Assembly and erection

Erection steam drums accordance with the manuals and drawings.
4. RESPONSIBILITY
4.1. Chief Construction
Responsible for the overall planning, coordination and control of erection
work.
4.2. Field Engineer
Responsible for field erection work implementation and maintaining
acceptable quality standard.
4.3. Field Superintendent and Supervisor
Responsible for the actual performance of the erection crew and examine
the actual progress of work to ensure that it fit the drawing, specifications
and standards.
4.4. Quality Control Engineer
Responsible for monitor and inspect the erection activities to ensure it is
being done in compliance with procedure, ITP (Inspection and Test Plant),
drawing, Project specification and other reference standard document and
procedures.
4.5. Supporter Activities
These activities will support by Material Control, Quality Control, Welding
Section, and others section related with these activities.
5. BASIC REQUIREMENT
5.1. Schedule and Planning
Master schedule is usually provided by Main Contractor. The detailed
schedule is prepared by Contractor according to his planning which is based
on Main Contractors master schedule. The milestone and the critical path
can be identified which require proper planning. The sequence of erection
activities and the resources required is included in the planning.
5.2. Erection Drawing and Erection Manual
Erection drawing and manual usually provided by Vendor. The Field
Engineer and Superintendent shall check all drawings intended for Steam
Drum Erection. All the information required is completed and all drawings
shall be of latest revision.
5.3. Packing List
Packing List shall be provided by Vendor. This included all the listing of
materials, equipment and parts that are supplied.

HaGun Institute

Document No :
Hg-Rig-002

Rigging Plan for Lifting

Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
SITE MANAGER

Date :
04/Apr/2012
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The Packing List should indicate the quantity of the material and equipment
supplied and its specification as described in the erection drawing. This will
also indicate the size and the total weight of the component and the method
of storage. Also the packing number and material coding is very essential.
5.4. Storage Area and Warehouse
Upon a thorough check on the drawing and the packing list, the quantity of
materials and equipment is already known, including the method of storing,
the size of the storage area and the warehouse can be identifies.
5.5. Resources
Identification of resources is integral part of planning and scheduling is the
most essential part of the basic requirement in undertaking Structure Boiler
2x110 MW Project in particular and in all jobs in general. Resources means,
the materials, labour and equipment needed to perform Structure Boiler
2x110 MW Project.
6. PREPARATION WORK
6.1. Checking of Steam Drum Erection Drawings
This has to be done by the Chief Construction, Field Engineer,
Superintendent and Supervisor to determine the correct resources needed to
perform the job.
6.2. Checking of Client Supplied Material and Equipment
Checking and inspection of the materials and equipment including the spare
parts is to be done by the material control. He will make sure that all
materials, equipment and spare parts received from Main Contractor,
conform to the quantity and the specifications started in the packing list or
shipping.
6.3. Checking of Erection Materials, Equipment, Tools and Machinery
In the early stage of planning, these resources had been already identified.
The schedule of mobilization ason planed schedule made by the Chief
Construction and Engineer.
Checking of Labour
Labour requirement for every stage of erection job is prepared by the Chief
Engineer and his erection team, which is in accordance to their planning.

HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
SITE MANAGER

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7. ORGANIZATION CHART

8. STEAM DRUM ERECTION SEQUENCE

It is assumed in this procedure that before starting the erection of the Steam
Drum, the supporting structure were already erected and checked by others and
clearance to proceed with the Steam Drum System erection had been obtained.
The following sequences are for reference only. During actual field assembly,
refer to lifting procedure and erection drawing (Rigging plan).

HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
SITE MANAGER

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8.1. REMARK:
The length of steam drum is 16436 mm and the span between grid G2 and
G4 at ELev. 46500 mm is 18000 mm. Therefore, the drum no needs to be
tilted. The electrict winch will be mounted on support. The movement and

HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
SITE MANAGER

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Date :
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restraint will be by chain blocks. The electrict winch will be operated from an
electric current. The actual loads on electrict winch as the drum are 7 ton, in
actual load at pulley are 35 ton.
8.2. PREPARATION WORKS:
Preparatory works such as strand guides and temporary scaffold access plat
form at top deck steel for jack operators and erectors and other levels
access for watchman at various elevations must be prepared in advance.
9. LIFTING PROCEDURE OF 72 ton BOILER DRUM
1. Drum shall be delivered with center offset towards grid K1.
2. Restrain the end of drum at grid K1 with chain blocks to prevent drum from
hitting the column at grid K1 during its initial lift off.
3. Lift the drum by approximately 100mm and hold it for 15 minutes while all
direct load bearing temporary and permanent girders and beams, winch
system are checked for any undue deflections or connections (steel/hose)
non conformities.
4. Once the system has been cleared for safe lifting, the wood/steel/concrete
blocks that are supporting the drum at ground floor are removed.
5. Lift Winch 1 and Winch 2 by slowly.
6. At this position, the drum shall clear the steel on both sides. A continuous
monitoring on the condition of the lifting system shall be done. The
watchmen shall continuous follow the drum while on its way up to check for
any obstruction along the way of the drum. If there is any obstruction the
watchmen will inform the lifting controller to hold the lifting until the
obstruction is cleared, then resume lifting.
7. Lift both ends together until the highest end is clear - above the Elev. 46500
mm.
8. Lift the drum until U-Bolt connection can be made.
9. After U-Bolt installation is complete, transfer the load from the lifting cables
to the bolts.
10. The lifting device shall be dismantled together with the temporary support to
clear the way for erection work to progress.
10. LIFTING TOOLS
1.
2.
3.
4.
5.
6.
7.
8.
9.

Electrict Winch capacities 10 ton

Tacle Block capacities 50 ton
Rolling Block capacities 15 ton
Rolling Block capacities 5 ton
Shackle Omega capacities 50 ton
Chain Block capacities 10 ton
Temporary Hanger capacities 50 ton
Sling 22 mm 500 meter
Wire Clip 7/8 inch

: 2 unit.
: 4 unit
: 6 unit
: 1 unit
: 2 unit
: 2 unit
: 2 unit
: 2 unit
: 6 pcs

HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
SITE MANAGER

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Date :
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11. RIGGING ANALYSIS

11.1.

Winch

Base-mounted winches, or tuggers, are a compact, versatile tool for many hoisting
and pulling operations. They are particularly useful in areas not accessible to mobile
cranes or where there is not enough headroom for a crane to operate. Figure 1
shows a tugger and snatch block arrangement for hoisting. Make sure that the rope
leaves the drum at a downward angle and that the loose end is securely anchored.
11.2.

Load Distribution

Figure 1

Load of Steam Drum 72 ton

Accessories 8 ton
Total Load 80 ton
Load distribution everi point
Load =

11.3.

80 ton
= 40 ton
2 Point

Anchorage Points

Hoists, winches, tirfors, and other rigging devices require secure anchorage points.
Anchors may be overhead, in the floor, or at lateral points in walls or other
structures. The arrangement may involve columns, beams, beam clamps, welded

HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
SITE MANAGER

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Hg-Rig-002

Date :
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lugs, slings, or block and tackle. Whatever the method, riggers must be certain of the
loads involved and the anchorage required.

Load
Parts of Line at Load
40 ton
Lead Line Load =
= 6,667 ton ~ 7 ton
6 line
Lead Line Load =

Load on structure = Load + Lead Line Load

Load on structure = 40 ton + 7 ton = 47 ton
11.4.

Safety Factor of Sling

Sling installed diameter 32 mm (1.25 inch) with capacities 17.70 Ton.

Safety Factor of Sling =

Sling Capacities 17.70

=
= 2.53
Load of Sling
7

HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
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Figure 2 Jarak minimum antara ke-dua Pulley Block 1888 mm.

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
SITE MANAGER

Figure 3 Hangger Arrangement

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
SITE MANAGER

Figure 4 Winch Arrangement

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
SITE MANAGER

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Date :
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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
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12. LIFTING ARRANGEMENT

Figure 5

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
SITE MANAGER

Figure 6

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department
13. WINCH ARRANGEMENT

Figure 7

.
Figure 8

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

Figure 9

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department
14. U BOLT HANGER INSTALLING

Figure 10

Preparation for U bolts arrangement.

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

Figure 11

U bolt and steam drum connected.

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

Figure 12

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

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SITE MANAGER

Figure 13

Connect U Bolt to Sling (lifting tools).

Steam Drum at elevation +47750 mm.

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
SITE MANAGER

Figure 14

Lift U Bolt until true elevation by slowly.

Ajust top of U bolt elevation by chain block.

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
SITE MANAGER

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Hg-Rig-002

Date :
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Figure 15

After U bolt in true position, steam drum is degrading by slowly to true position on U
bolt.

HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

Figure 16

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
Rigging Department

APPROVED BY:
SITE MANAGER

Figure 17

U bolt install and rigging arrangement for lifting.

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
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APPROVED BY:
SITE MANAGER

Figure 18

U bolts and rigging tools Arrangement.

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
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Figure 19

Pulleys hangger is arrangement.

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
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Rigging Department

Figure 20

Dimension of hanger.

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
PREPARED BY:
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15. TEMPORARY HANGER CAPACITIES 50 TON

Selected Face(s)

Von Mises Stress

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
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Displacement

Safety Factor

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HaGun Institute
Rigging Plan for Lifting
Steam Drum 72 Ton
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16. ACTUALY

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