A high precision SyncHoist system from Enerpac (A Division of Actuant Corp) has been successfully deployed by heavy lift and transport specialists Universal Cranes on a project for the Royal Australian Navy.
The Enerpac lift system deployed by Universal Cranes for the Landing Helicopter Deck (LHD) vessel project under way at Williamstown, Victoria is being introduced to Australasia to enhance crane performance and safety in diverse heavy lift projects across various industries. The SyncHoist system will ensure optimum accuracy and safety in the hoisting and positioning of key components on one of the largest ships ever built for the Royal Australian Navy.
Universal Cranes integrated the system with a 600 tonne crawler crane as part of the project management and engineering for the consolidation of steel blocks weighing 164-300 tonnes on the deck of the first of the LHD vessels being built by BAE Systems Australia. The four steel blocks with variable centres of gravity will become the operating control towers on the flight deck of the Canberra class LHD, one of two 28,000 tonne LHD vessels that will come into service in 2014 (HMAS Canberra) and 2015 (HMAS Adelaide) respectively.
BAE Systems Australia is prime contractor for the project, which includes superstructure fabrication at Williamstown (Melbourne) and Henderson (WA), and ship consolidation at Williamstown.
The Enerpac SyncHoist system involved in the construction of the Canberra offers load manoeuvring vertically and horizontally using one crane, aligning the block for the crane to lower it.
Employing intelligent hydraulics to monitor and guide compact but powerful 700 bar double-acting push-pull cylinders integrated into four lifting points above the loads, the SyncHoist SLS system can be used for pre-programmed positioning, tilting and aligning of loads and for counterweighting and determining their centre of gravity.
Manual control options for the four lifting points with 1500mm system reach include manual control with manual directional control valves, extended manual control with joystick controls and position display, and PLC control with fully closed-loop control system. PLC control options include touch screen, remote wireless control, load and stroke monitoring, load calculations (centre of gravity) and pre-programmable motions and data recording.
According to Universal Cranes Heavy Lift Engineer Mr Nick Morris, the size of the vessel made the use of traditional craneage and dry dock option unfeasible. The Demag CC2800-1 crawler crane was rigged with a 72m main boom in Superlift Lift (SSL), and positioned to work from the Nelson Pier adjacent to the moored LHD vessel.
BAE Systems designed and built a steel grillage to purposely match the characteristics of Universal Cranes’ CC2800-1 crawler crane and allow positioning on the pier. The grillage, weighing approximately 600 tonne, allowed the crane to be positioned on the pier structure with loads effectively transferred directly to the lower piles. The grillage was then relocated by the crane in preparation for each sequential lift.
Universal Cranes purchased a 440t Enerpac synchronised hoisting system specifically for the LHD project. Comprising of four hydraulic cylinders each capable of 110t and offering a stroke of 1500mm, the system can be installed within a rigging arrangement in tension providing an overall capacity of 440 tonnes.
Mr Morris observed that the SyncHoist allowed a gradual lift of the load, and dynamic adjustment in relation to the centre of gravity during the lift, enabling constant monitoring of load and stroke on each cylinder and ensuring very accurate control by the operator.
The Enerpac SyncHoist system for cranes is a member of the Enerpac synchronous lifting family, different members of which have been employed globally on jobs as diverse as lifting the Golden Gate Bridge in San Francisco, manoeuvring the roof of the Beijing Olympics Birds Nest Building, hoisting 1000-tonne mining mills in Western Australia and re-levelling multi-storey buildings after the Christchurch earthquakes.
Key features and advantages of SyncHoist synchronous lifting systems:
- Use of one instead of multiple cranes, making particular lifts less difficult and risky
- High accuracy, eliminating damage to loads
- Reduces the impact of weather conditions, which play a less critical role in comparison to applying multiple cranes
- Available in system load capacities of 40-1000 tons
- System reach of 1500mm from each lifting point
- Very high accuracies (+/- 1mm)
- Vastly improved operating speed and worker safety
- Available with manual, advanced and fully controlled lift management systems
- Diesel or electric power
Specific applications include:
- Positioning of roof sections, bridge sections, concrete elements, and steel structures
- Positioning of turbines, transformers and fuel rods
- Precise machinery loading, mill rod changes and bearing changes
- Precise positioning of pipelines and blow out valves
- Positioning and aligning of ship segments prior to assembly