highlights edition 5

Reaching foR success Safely pushing ahead with global expansion

edition 5 HigHligHts 2

contents

03 RecoRd-BReaking Load outs in the uae

AJHL’smemorabledeliveryonalandmarkproject

05 heavy duty down undeR

Buildingonasolidreputationasaleading heavyliftprovider

06 PoweRing uP in BangLadesh

AJHLemergesasavitalassetonnationalgasagenda

07 deLiveRing exceLLence as standaRd

AJHLprovesitisakeyplayerinQatar

09 aJhL Makes MuLtitasking Look easy

Coordinatingcomplexheavyliftsischild’splay forAJHLcrew

10 Leading Load out oPeRations oveRseas

ImpressivecollaborationinIndonesia

12 BReaking woRLd RecoRds at Ruwais

Flexingmuscleatoneofthelargestoilrefineries

13 sMooth saiLing thRough the BosPoRus

Multitaskinghelpsconquerintricatelifting assignmentinTurkey

14 exPanding its gLoBaL Reach

MajorprojectinKSAisaresoundingsuccess

15 navigating the unconventionaL

AJHLSingaporeembraceschallengesonthe JurongPortProject

16 Joint teaM effoRt

AsiaOffshorefacesitsmostambitiousprojectyet

17 in safe hands

Maintaininghighestsafetystandardsiskeytosuccess

19 on tRack foR success

Takingthestrainonprestigiousrailproject21 tRaining foR the toP

Advantagestoinvestinginthelatestcranesimulators

22 on heavy duty

LiftingSuperintendentMohammadAnwar marksover30yearsatAJHL

in thiS iSSue

07

0313

welcome

AwarmwelcometothefifthissueofHighlights.Here,wecelebrateourrecentsuccessesandlookforwardtothemultitudeofchallengesthatlieahead.

ThesearebusyandexcitingtimesatAlJaberHeavyLift(AJHL).Ourhighlyskilledworkforcehassafelycompletedsomeastonishingheavydutyprojectsinthelastyear,andachievedimpressivesafetyrecordstoo.

Teamspiritsarerunninghighasweforgeaheadwithourcommitmenttoprovideclientswiththemostcomprehensiveheavyliftandtransportationservices,bothforonshoreandoffshoreindustries.

Asuccessfulcompanyisbuiltuponitsemployees.Thankstoourdedicatedtechnicalandengineeringcrews,whoaresupportedbyaskilledmanagementteam–nottomentionafleetofworld-classequipment–wearecapableoftakingonthemostexcitingandcomplexheavyliftdutiesanywhereintheworld.

What’smore,ourclientsrecogniseoursuccess–totheextentthatoneclientrecentlyheldaceremonytothankallthesubcontractorsforhelpingthemtoachieve100millionincident-freemanhoursontheirproject.

Aswelookforwardtobuildinguponourinternationalportfoliointhemonthsahead,weextendawarmthankyoutotheAlJaberfamilyfortheirongoingsupportandguidanceinthedevelopmentofAJHL.

WehopeyouenjoyreadingthislatesteditionofHighlights.

Alexander MullinsExecutive Director, Al Jaber Heavy Lift Group

edition 5 highlights1

edition 5 HigHligHts edition 5 HigHligHts 43

AJHL delivers on a series of impressive load outs requiring precise preparation, engineering and execution

RecoRd-bReaking load outs in the uae

AJHL’sengineerswereengagedwiththeclient’sengineersandtechnicalpersonnelfromthebeginningtofinalisetheoptimalconfigurationofthetrailerandlayoutforeaseofplacingofthetrailers.

engineeRed to PeRfectionAtotalof232hydraulicaxlelinesofSPMTs(self-pro-pelledmodulartrailers)weredeployedfortheloadoutoperation.SPMTswereselectedforthisloadoutoperationthankstotheir360-degreemanoeuvrability,40Temaximumpayloadcapacityperaxleline,andtheabilitytoconfigurethemasperon-sitespacingneeds.

Assemblingall232axlesindifferentcombinations,witheightpowerpacksandtheirmechanicalandelectricalcouplings,wasaccomplishedinjustoneday.Dataconnectionswerecompletedsothatallpowerpacksandaxleswerecontrolledbyoneremotecontrolunitforfasterandprecisecontrol.

Themostdifficultpartwasmanoeuvringandar-rangingtheaxlesundertherighull.Trailerpathsweremarkedunderthehullasperthestoolarrangementonthebarge,andtrailerswerecarefullyplacedreadyforthejackupandtransportationoperation.

exPeRt handLing

Loadoutoperationoftherigwasscheduledfor6amtocoincidewithfavourabletideconditionsforoptimumsafety.Thedistancebetweenthetwotowingbracketsonthesternsideofthebargewas27.9m,whilethetotalwidthofthetrailerconfigurationwas27.5m.Thisleftaclearanceofjust20cmfromtheSPMTtyrestothetowingbracketoneachside.

ThankstoAJHL’sskilledoperatorsandcrew,theteamprovedtheirexpertiseinrespondingproactivelytoclient’srequirements–andexceedingexpectations.TheclientwassoimpressedthattheyautomaticallyawardedeachsubsequentloadouttoAJHL,withoutinvitingotherfirmstotender.

What’smore,thecustomerwasdelightedthatthedeadlineoftransportingandloadingouttherigwasmetontheexactdayitwasscheduled.Thisenabledtheclienttocompletethefloatoffontime,movetherigbacktoHamriyahforthecompletionofthefabricationworkandfinallydeploytherigforoffshoreoperation.

AJHLensuredasmoothandsafeprojectcomple-tion,withnolosttimetoaccidentorbreakdown.TheimpeccableexecutionreinforcesAJHL’sreputation,anddemonstrateswhyclientsacrossthegloberepeatedlyengageitsservicesforthemostcomplexoperations.

AJHL’sAbuDhabiteamsuccessfullyfinishedaseriesoflandmark,heavyloadoutprojectsforoneoftheUAE’sleadingspecialistsin

offshoredrillingrigsandplatformfabricationandrefurbishment.Overthecourseofoperations,thecrewcompletedarecord-breakingsixloadoutsforanoffshorerigontoasemi-submersiblebargeattheclient’sfabricationyardinHamriyah,Sharjah.Eachloadoutweighedbetween6,000Teand7,000Te.

Theclientunderstoodfromtheoutsetthattransportingandloadingoutarigofthissizewouldinvolvenumerouscomplexities,andsoitinvitedAJHLtostudyandsubmitaproposaltocarryouttheoperationsafelyinthepre-engineeringstage.Basedonthis,AJHLwasawardedthejob.

Therighullhadtobetransportedfromthefabrica-tionareatothequaysidefortheloadoutontothesemi-submersiblebarge.Thiswashighlychallengingfromsafety,technicalandcommercialperspectives.Therigweighed6,300Teandmeasured74.09mlong,62.78m

wideand7.92mhigh.But,withthetrailersandauxilia-rysteelworks,thetotalloadreachedacolossal7,284Te.

OneofAJHL’sbiggestchallengeswasmobilisingthevastnumberofaxlesneededforthejobfromdifferentbranchesandsitesaroundtheworld,witharound98ax-lesshippedfromSingaporeandQatarhubsinadditiontotheonesavailablelocally.

Akeyperiodofthejobwastheextricationandmobilisationof104axlesfromRuwaisinAbuDhabitotheHamriyahprojectsite,whichAJHLachievedinanimpressivetwodaysintimefortheloadout.

“Assembling all 232 axles in different combinations with eight power packs was accomplished in just one day”


AJHL builds upon its solid reputation in Australia as a leading heavy lift provider AJHL’srecentinvolvementononeofthe

largest-producinggasfieldsinBangladeshprovesithasthetechnicalknow-howto

overcomeheavyliftingchallengesanywhereintheworld.

InJuly2012,theclientannouncedmajorplanstodevelopitsBangladeshioperations.Thisincludedanambitiousgasplantexpansion,newdevelopmentwellsandanenhancedliquidsrecoveryunit,designedtoincreasethetotalmaximumdailyproductionbymorethan300millioncubicfeetofnaturalgasand4,000barrelsofcondensate.

AJHLprovidedtheliftingservicespackagefortheplantexpansion,whichcalledforfivemobilecranesandone275TecrawlercranetobedeployedforeightmonthsfromJuly2013.

AllequipmentwasshippedfromSingaporetotheBangladeshiportofChittagong,andthenroadfreightedtotheprojectsiteapproximately500kmaway.Logisticalchallenges,coupledwiththeproject’sremoteness,meantaconcertedeffortwasneededtoensurethetimelyon-sitedeliveryoftheequipmentinordertomeettheproject’sexpectations.

heavy duty down undeR AJHL is a vital asset in the country’s

ever-increasing demand for natural gas

PoweRing up in bangladesh

cRuciaL stages

AswithallAJHLoperations,safetywastheprimaryconcernfromtheoutset.Eachload-outoperationhaditsownpre-definedriskassessmenttoidentifypotentialhazardsateverystage.

Furthermore,strategiccoordinationwasrequiredtomonitortheequipment’sdeparturefromSingaporeuntilitssafearrivalattheprojectgate.ThisrequiredverycarefulinterfacebetweenAJHLSingapore,theclientandthirdparties,toensurethesmooth,on-timedeliveryofallmachinery.

AJHLhascompletedanenvironmentally-sensitivejobonaliquefiednaturalgas(LNG)projectonBarrowIsland,70kmoffthecoastof

WesternAustralia.TheprojectinvolvestheconstructionofanLNG

productionfacilityontheisland,aClassAnaturereserve.ItwillbeoneofAustralia’ssinglebiggestdevelopments,withanestimatedresourcebaseofmorethan40trillioncubicfeetofgas,andadevelopmentlifeofaround60years.

Theclient,agloballogisticscompany,hasthecontractforfreightforwarding,unloading,dischargeandtransportofmaterialssupplytoBarrowIsland,aswellasthelogisticscontractforthereceivinganddistributionoffreightfromaload-outfacilitydevelopedforhandlingmaterialontheproject.

AJHLwastaskedwithtranslatingtheconceptofatemporaryloadingwharfintoamanageablehandlingfacility,withtheuseofabargeandcrawlercranetoretainaflexiblewharfreceivingfacility.

enviRonMentaLLy awaRe

EnsuringAJHL’splantwascorrectlypreparedforworkinaClassAnaturereservewasanimportantpartofthisjob.

Allcranedata,includingmaterialsafetydatasheets,onbargeengineering,liftingstudies,assemblymethodsetc,werepre-preparedwhilsttheplantwascleanedandwrappedforcarefulshipmenttotheisland.

SkilledsupervisorsandoperatorsassistedmobilisationbeforeAJHLbuilttheplant,hadittested,licensedandcertifiedonbargeforfinaloperationbytheclient.

Despitethechallenginglocationandconditionsofthisoperation,suchasworkinginahighheatandharshhumidenvironment–nottomentionbeinginthemidstofacyclonebeltandworkingonabarge–AJHLhasmaintainedazeroLTIandhighlycommendable100percentzerobreakdownrecordforthisplanttodate.


AJHLisplayingasignificantroleinhelpingQatarmeetitsgrowingdemandfordomesticgas,asdemonstratedbyitscrucialinvolvement

inamajoronshorefacility.Thevastprojectincorporatesagasprocessing

unit,sulphurrecoveryunitandanNGLrecoveryunittoproducemethane,ethane,propane,butaneandcondensate.TheclientwasawardedtheEPCcontracttobuildthegasprocessingfacilitiesfortheproject,locatedinRasLaffanIndustrialCity,80kmnorthoftheQataricapital,Doha.AJHLwastaskedwiththecomplextransportationandfinalinstallationofamassive147piecesofequipment,rangingfrom100Teto1,330Te.

facing chaLLenges

Threemajorchallengeswereidentifiedfromtheoutset.Firstly,therewasthedelicateengineeringtaskofinstallingtwoAGR(acidgasremover)absorbers,eachweighing1,330Te,intwotrainsintheminimumtime.SecondlywasAJHL’suseoftailingframetechnologyforthesuper-heavylift,withtheinductionofa1,000Tetailingframe.Finally,therewerestringentsafetytargetsthathadtobeachievedwhilstworkingalongsideothercontractors.Withatotal27,000peopleonthesite,itwasimperativetoallowotherstogetonwiththeirworkandnotblockvitalaccesspoints.

Workofthisscalerequiredacomplexraftofequipment,includingaDemagCC8800-1,twinkit,aDemagCC2800-1,aDemagCC2500-1,DemagAC-160,theHitachiSumitomoSCX2500,1,000Tetailingframe,124axlesofScheuerleSPMTs(self-propelledmodulartransport),48axlesofComettoMSPMs,anda36-axleconventionaltrailer.

cRiticaL tiMing

Theteamwasespeciallyvigilantduringcriticaltimessuchascheckingboomclearancefortheinstallation,aswellasproperutilisationofallavailableliftingtackleforbotheasierandfasteroperations.Inparticular,carefulattentionwaspaidtosafetyatheightaswellasunderaloadwhilsttailingthe1,330Teabsorber,forwhichspecialcriteriawasfollowedinaccordancewithAJHL’sstrictriskassessmentprocedures.

SuchwasAJHL’scommitmenttosafetythattheteamcompletedtheirworkwithanoutstandingzeroincidentoraccident.What’smore,theclientheldaceremonytothankallthesubcontractorsforhelpingthemachieve100millionincident-freemanhoursonthisproject.ThisisallthemoreimpressivegiventhatAJHLfieldedacrewof73includingprojectmanagement,engineeringandsafetymanagement–andyetwasresponsibleforliftingandtransportingequipmentwithacombinedtotalweightofmorethan52,000Te.

AJHL’ssafetystrategies,qualityprocedures,engineeringcapabilitiesandstrongclientrelationshipcontributedtoitslandmarkachievementonthiscomplexproject,andhelpedunderlineitsreputationfordeliveringexcellenceasstandard.Asalways,AJHLstrivestogotheextramiletosurpassexpectations.

World-class expertise in providing heavy lifting for the gas industry makes AJHL a key player in Qatar’s onshore projects

delivering excellence as standard



Singapore

Coordinating complex lifts of varying weights and sizes is all in a day’s work for AJHL’s crew

Early communication, planning and coordination were key to AJHL’s successful client collaboration

leading load out operations oVeRseas

Whenaleadingspecialitychemicalcompanydevelopedahigh-techbutylrubberplantonJurongIslandinSingapore,AJHLwas

taskedwithprovidingheavyliftservices.The100,000metrictonne-capacityplantisthe

mostmodernofitskindinAsia.Whenoperatingatfullspeedin2015,itwillproducepremiumhalobutylrubber,aswellasregularbutylrubber.AJHL’sremitinvolvedtheheavyliftingofvesselsofvaryingweightsandsizes,andinstallingthemontothefoundation.Thediversityofliftjobsinvolvedcranesrangingfrom120Teto1,250Tecapacity.

technicaL know-how

Meticulousplanningwasrequiredforthemobilisationofthemaincrane,aDemagCC8800(1,200Tecapacitycrawler)totheprojectsite.ThiswasachievedbycarefulliaisonwiththeSingaporeportauthorities,trafficdepartmentsandlocalbodies,toobtainthenecessarytransportpermitsandpermissions.

LinershipswereusedtotransporttheDemagCC8800toSingapore,andfromtheporttositethecomponentswerecarriedbylow-bedtrailers.

keePing to scheduLe

Onceattheprojectsite,measuredcoordinationwasneededwiththecivildepartmenttoestablishtheoptimumground-bearingpressureforheavylifting,aswellasovercomingtheuncertaintiesofday-to-dayhurdlesinordertoadheretotheclient’scarefullyplannedschedule.

Anin-depthtechnicalstudywasrequiredtofixthepositionoftheDemagCC8800tocarryouttheheavyliftingoperationsatsite.Ourengineeringteamplannedthissothatallheavyliftscouldbeachievedfromonesinglecraneposition.Inaddition,aDemagCC2400(400Tecrawlercrane)wasused,aswellasaHitachiSCX2800,aDemagAC-500andaDemagAC-120fortailingoperationsandforcarryingoutthesmallerlifts.

Aswithalltime-criticaljobs,planningandcommunicationformedacriticalelementthroughouttheprocess.Onthisproject,in-depthplanningwascarriedoutacrossalldisciplines,whichresultedinAJHLproposingthatthedressingupofvesselsbeperformedintheinitialhorizontalstage,whichinturntranslatedintosignificanttimeandcostsavingstotheclient.

making the most of multitasking

Whentheclient,aleadingengineeringandconstructionfirm,decidedtoloadoutmorethan60pre-assembledstructures

attheBatamIslandfabricationfacilityinIndonesia,itengagedAJHL’sexperthelp.Upagainstmanyglobalcompetitors,AJHLwasdelightedtosecuretheproject,theirfirstcollaborationintheregion.

eaRLy inPut

Initially,AJHLdesignedandproposedaspecialsynchronisedjackingsystemwhichmettheclients’re-quirements.Asthepre-assembledracksandunitshadacombinedweightofapproximately25,000tonnes,equipmentwasselectedbaseduponvariousconstraintsincludingweight,size,themodulesupportpointsandsiteconditions.Thesynchronisedjackingsystemincludedeight125Teclimbingjacks,1,600piecesofjackingtimber,136axlelinesofSPMT,eightPPUsandfour12mramps.

Oncetheclientapprovedtheequipment,AJHLcarriedoutacomplexjackingoperationfollowedbyinternalshiftingofthepancakemodulesduringthefabricationstagesofthecontract.AJHLwasthenresponsibleforloadingoutthestreamofpiperacksto

theshipsinaroll-onoperationduringdeliverystage.Astheclient’scustomersarepredominantly

governmentutilities,powergeneratorsandoilcompanies,theteamdiagnosedandanalysedpotentialrisksandhazardsinthefield.

winning coMBination

Theprojectfinishedonschedulewhenthepre-assem-bledstructureswereinstalledattheliquefiednaturalgasplantonBarrowIsland,Australia.ThisprojectthereforehadtoadheretoAustralia’sstrictstandards.Aftersuccessfullyjoiningforces,thisAJHLload-outprojectwasawinningcombinationofplanning,com-municationandcoordination.AJHL’sclosetieswiththeclientwillundoubtedlyleadtofuturecollaborations.

“The synchronised jacking system included eight 125Te climbing jacks, 136 axle lines of SPMT and four 12m ramps”


AJHL flexes its muscle to transport and safely install the world’s largest crude column to date

Breaking woRld RecoRds

at ruwais

AJHLcontinuesitsprojectsuccesssafelywiththecompletionofamilestoneprojectatoneoftheUAE’slargestoilrefiningfacilities

inAbuDhabi.Theexpansionprojectincludestheconstructionofacrudedistillationunit,forwhichAJHLwastaskedwithhandling145,000FRT(freighttonnes)ofprojectequipment(includingtheworld’slargestcrudecolumntodate).

Theclient,aninternationally-recognisedEPCcontractor,neededtheprojectequipmenttobereceivedatAbuDhabiPortandthentaken(bylandorbyacombinationofmarineandlandtransportation),tothesiteinRuwais,200kmaway.AJHLthenhadtolifttheequipmentontothefoundations.

Oneofthebiggesthurdlestoovercomewasthehandlingof145,000FRTofheavy-liftequipmentatAbuDhabiPortwithinatimespanofjusteightmonths.

Furthermore,thesafetransportationofthevastamountofequipmenttositerequiredcarefulcoordinationwithlocalauthorities.Upondeliverytosite,thesuccessfulliftingoftheequipmentontothefoundationcalledforafleetof17cranesrangingfrom100Teupto3,200Tecapacities.

Finally,eachpieceofequipmenttobetransportedanderectedvariedintermsofgeometryandweight,whichdemandedcarefulassessmentbeforefinalisingthetransportationandliftingprocesses.

stRategic PLanning

AJHL’sengineeringteamwasinvolvedwiththeclient’sengineersandtechnicalpersonnelfromthepre-biddingstage,todeviseanoptimalsolutionfortheoverallproject.Technicalclarificationmeetingswereheldwiththeclient’sengineerstoevaluateequipmentrequirementsandtoinitiateplanstomeettheproject’sschedule.Earlyinvolvementhelpedtoensureallrelevantaspectswereconsideredintheplanningstages,beforeanyequipmentorpersonnelwerebroughttosite.

Planningsessionswerealsoheldtostrategisetransportationandinstallationmethods,discussrisksandmeasurestakentomitigatethoserisks.

setting a new standaRd

Theheaviestcolumnfortheplantweighedinat1,261Teandmeasured94mlong,witha12.5mdiameter.Atthetimeofoperationsthiswasthelargestcrudecolumntobehandledanywhereintheworld.

AJHLproposedtouseamarinespreadofa350-feetclassbargeanda50Tebollardpulltugboat,alongwith76axlelinesofself-propelledmodulartrailersfortheload-outandload-inoperations.Inaddition,a3,200TecapacityDemagCC8800-1withtwincrawlerattachmentwasdeployedtoinstallthecrudecolumnontothefoundation.

Fromthestart,thiswasahighlychallengingprojectfromsafety,technicalandcommercialperspectives.

attention to detaiL

OneofAJHL’skeystrengthsishavingalltheskillsandexpertisetodevelopcomprehensiveengineeringpackagescomprisingmethodstatements,riskassessmentsandriggingstudies.Thesethenformtheblueprintsforoperations,andcontainalltherelevantinformationtoensureworkisconductedtothehighestpossiblesafetyandqualitystandards,toensureclientsatisfactioneachandeverytime.

InadditiontohavingaccesstotheconsiderableresourcesofthewiderAlJaberGroupofcompanies,AJHLpridesitselfuponitsabilitytofocusonthesmallestdetailsineachoperation.

ThislandmarkrefineryexpansionprojectisyetanotherexampleofhowAJHL’smeticulousplanninglaysthefoundationsforoutstandingresults,whetheroverseasorathomeintheUAE.

“Successful lifting of the equipment called for a fleet of 17 cranes ranging from 100Te up to 3,200Te capacities”


Intricate lifting assignment in Turkey proves AJHL’s strength in multi-task project management

smooth sailing on the bosPhoRus

ThebridgeovertheBosphorusStraitinIstanbulhaslongbeenastrategicgeographicalcrossroadswhereeastmeets

west,andwhereEuropeendsandAsiabegins.Witha65mverticalclearance,however,thebridge

canalsoproveasignificantobstacletomaritimetraffic–inparticularlargedrillingvessels–whichmusttraversetheStraitontheirjourneystoandfromEurope,CentralAsiaandtheMiddleEast.Withvastamountsofcrudeoilandnaturalgasreservesinthesurroundingregions,todaytheBosphorusStraitrepresentsacrucialenergycorridorwhichmustbenavigated–bridgeornobridge.

AndsoitwasthattheclientengagedtheservicesofAJHLforahigh-precisiontask:toremovethederrickstructureofasizeabledrillingship,transportthederricksectionsunderneaththebridgeandalongtheBosphorusStraitbeforereinstallingthemontotheship,soastoenableitssafepassageunderthebridge.OncethevesselarrivedatSamsunPortontheBlackSea,thederrickwasscheduledtoberemovedinseventechnicallifts.Thederrickwouldthenbeloadedontoabarge(contractedbyAJHL)andtakentoBandirmaPortontheSeaofMarmara,whereitwouldbereinstated.

Thiswasinfactthedrillingship’sreturnjourney–theclientwassoimpressedwithAJHL’sperformanceontheoutwardjourneyoneyearearlier,thatAJHLwasthenaturalchoiceforthisreturnleg.

AJHL’sscopeofworkencompassedeverythingfromthearrivalofthevesseluntilthereinstatementofthederrickstructure,includingcontractingandsupervisingtheports,organisingthebargeandseafasteningaswellasperformingthelifts.InSamsunPort,a17-strongworkforcefromAJHLwasonsiteusingaDemagCC8800-1toremovethederrickstructure,whileinBandirmaPorta16-memberteamusedaCC8800-1Twinforthereinstatement.Bothteamswereoperationallyself-sufficient.

siMPLifying oPeRations

Communication,accountabilityandcompletevisibilitywereessential.Despitetheintricacyofthetask,AJHLnotchedupoutstandingachievements:notonlywereoperationscompletedaheadofschedule,

theywerealsocompletedunderbudgetandwithoutlosttimeincident.TheprojectunderlinesAJHL’s

capability–notonlyinliftingandlandtransportationjobs–butinthemostcomplex,multi-taskproject

managementsituations.

AJHLrecentlyundertookacomplexheavyliftpackageforaprestigiousacrylicacidprojectinJubailIndustrialCity,KSA,foritsclientand

theclient’sconsortiumpartner.Thescopeofworkincludedliftingaround26pieces

ofequipment,withweightsrangingfrom75Teto770Te.Forthis,thehighlyexperiencedAJHLprojectteamdeployedaDemagCC8800(1,250Tecrawlercrane),aDemagCC2400(400Tecrawlercrane),HitachiSCX2500(250Tecrawlercrane)andaDemagAC160(160Tetelescopiccrane).

WhiletheHitachiSCX2500andDemagAC160wereusedfortailingandriggingassistanceoperations,theremainingequipmentwasusedastheproject’smaincranes.

Oneofthemainchallengeswasliftingandpositioningstructuresatanextensiveradius;theheaviestpiece,a92Tetrusswasliftedata102mradiusandata38melevation.Thismeanttheconfigurationofthedeployedcranehadtoliftatapproximately90percentcapacity.

TheAJHLteambrokedownthemultifacetedprojectintosmallertaskstohelpeasetheoverallriskassessmentofeachsection,andhenceapplyAJHL’srigoroussafetystandardsalongwithsitesafetyregulations.Moreover,sharingsafetyconcernsanddrivingthemfrombottomleveltotopmanagementhelpedtoincreasetheprojectteam’sabilitytoassessanypotentialweaknesses,whichwerethenquicklydealtwith.

exeMPLaRy safety RecoRd

Byfullyunderstandingthecustomerrequirementsanddoinganin-depthanalysisoftheproject’sconstraints,AJHLinitiated,planned,executed,monitoredandcontrolledeachandeveryphaseoftheventure.Thiswasreflectedintheclient’shighlevelsofcustomersatisfaction,totheextentthattheyexpresslyrecognisedAJHLascontributingtoitsimpressiveachievementof10millionmanhourswithnoLTI.

ThisoperationdemonstratesAJHL’scommitmenttoprovidingsafe,qualityheavyliftingandtransportationservices,rightacrosstheglobe.

Major project in KSA for international engineering giant is a resounding success

expanding its global Reach


edition 5 HigHligHts15

AJHLSingaporewascontractedtoconstructacementoffloadingfacilityfortheJurongPortAuthority.Itwasassignedthedauntingtask

ofshippingandshiftingbulkcementandoffloadingtwodischargeshipsfromBatamtoSingaporeforeventualinstallationatJurongPort.

weighty issues

Lashingwasidentifiedasthemostcriticalchallenge.Theindividualweightoftheshipunloaderswereapproximately550Te.Toensuretheequipmentdidnotmoveonthebargedeck,theteamdesignedseafastingusingStraddProsoftware.Theresultwaseight150mmtubularlashingseachwithacapacityof55Teandanadditional2015Tewire-ropelashingsforextrasafetytocounteracttheanticipatedpitchandrollofthebarge.

Unlikeconventionalloadoutsachievedoverthesternorbow,AJHLSingaporehadtodischargebothshiploadersovertheside.Fourteenpumpswereemployedtomaintainacorrecthealandtrimonthebargeandthecompensationofpumpingwas

Crossing the world’s busiest shipping lanes was not the only obstacle AJHL Singapore overcame on the Jurong Port Project

an unconVentional load out

basedon700mmoftrailertravelatatime.Withallpumpsworkingthroughoutthedischarge,theprocesstookjusttwohoursand45minutes,fasterthanthepredictedthreehoursandanunprecedentedachievementforAJHLSingapore.

Addressingthemonsoonsthatplayedhavocwithseafasting,weldingproceduresandtimeschedulewasalsokey.Meetingthebudgetwasimperative,too,sotheteammobilised40axlesofSPMTtoBatam,enablingthemtoundertaketheload-inphasemoreefficiently.Fortheoff-loadingphase,AJHLSingaporeusedaxlesthatwerealreadybasedinthecitystate.

Multitaskingwasessential,withriggersbeingusedtoassistinballastingthebarge,andthesafetyofficertestingthegasandissuingthePermittoWorkdocuments.Ahighleveloftrustalreadyexistedbetweenbothparties,asAJHLSingaporehadcompletedaliftingprogrammefortheclientearlierontheproject.ThiswasatriumphantblendofprofessionalismandcooperationbetweentheAJHLengineers,thesiteteamandeveryoneonboard.

europe

A highly engineered fabrication assignment in Singapore proves AJHL’s ability in multi-task project management

joint team effort

WhenAsiaOffshore(asubsidiaryofAJHL)wasaskedtosupplyanintegratedboilermoduleforanFPSO(floatingproduction

storageandoffloading)fordeploymentintheNorthSeainEurope,itengagedparentcompanyAJHLtoassistwiththeheavyliftingduties.TheclientawardedAsiaOffshoretheprocurementandconstructioncontracttosupplytheboilermoduletotheFPSO,onbehalfofaUK-basedpetroleumproductionandexplorationcompany.

Rising to the chaLLenge

AsiaOffshorewastheregion’sfirstcompanytobuildamoduleofthiskindfortheNorthSea.At24mlong,17mwideand24mtall,themodulecomprisedfourlevelsofstructuralsteelincludinggasuptakeducts,intakeairductsandexhauststacks.

Furthermore,therewere280handrails,24staircases,platformsoneachlevel,pipingsteelwork,electricalandinstrumentation,insulationandheattracingtoaccommodatetheinstallationandfunctioningoftwo142T/hboilers,twoeconomisersandmorethan200instruments.

AsiaOffshoredividedtheentiremoduleintotwo,sothatbothhalvescouldbefabricatedsimultaneously.ItengagedAJHLtousethreeheavydutycranestoliftonemodule,andthenerectitontopoftheother.

A50Tecrawlercranewasdeployed,alongwitha90Temobilecranewithajibforgeneralworks.Sincethemoduleweighedapproximately720Te,AJHLloadedoutthemoduleontoabargeusingthree52-axleSPMTs.

DespitebeingtheheaviestandlargestmodulehandledbyAsiaOffshoresofar,workwasfinishedonbudgetandontimewithintheseven-monthjobduration.

edition 5 highlights 16

edition 5 HigHligHts edition 5 HigHligHts

xxx

1817

Maintaining the highest safety standards on hazardous projects is at the heart of AJHL’s global success story

Battlingintenseheatandhumidity,workingtotightdeadlinesandoperatinginhazardous,fire-proneconditionsareallinaday’swork

forAJHL’shighlyskilledworkforce.Thecompany’swealthofexpertisewascalledupon

inthesummertoassistinoperationsatarefineryprojectinYanbu,KingdomofSaudiArabia.

Processingmorethan360,000bpdofArabianlightcrude,thefacilitybeganoperationsin1982.Todayitistheworld’slargestsingle-traincrudeoilrefineryproducingLPG,gasoline,jetfuel,baseoilaswellasfueloil.AJHL’sinvolvementintheprojectwassplit

in safe hands

intotwophases:transportationandheavylifting.Together,thesetwoelementsformedanintegralpartofthefacility’sturnaround,ascheduledshutdown(whichtakesplaceapproximatelyeverytwoorthreeyears)toenableroutinemaintenanceandrepairstobeconducted.

coMPLex task

Thefirstphasecomprisedthetransportationofaregenerator(420Te),reactor(600Te),spiderbeamandtwooverheadlinesfromYanbuIndustrialPorttotheprojectlaydownarea,overapproximately6km.

ThemainchallengesAJHLhadtocontendwithandovercomeincludedworkingduringtheintenseheatandhumidityofsummer,delaysbythirdpartiesinshipmentarrivalandportclearance,aswellascarefulcoordinatingbetweentheRoyalCommission,PortAuthoritiesandthefacility’soperators.

Thesecondphaseinvolvedtheheavyliftingduringtheshutdown.Duringthistime,AJHLwascalledupontotransportvariouspiecesofequipmentfromthelaydownareatotheFCC(fuelcatalyticcracker)unit.

Themostcriticaljobhoweverwastheremovalandinstallationoftheregeneratorandthereactor.Here,AJHL’sheaviestliftsweretheregeneratorheadandcyclones(400Tenetweight)andthereactorshell(561Tenetweight).

oveRcoMing chaLLenges

Theprincipalchallengesoftheprojectweremeetingaverytightworkscheduleandoperatinginaconfinedarea,nottomentionmaintainingthehighestlevelofsafetyatalltimes.

Safetywasoftheutmostimportanceonthisproject,especiallysincethesitewasahazardousonewithriskofgas(H2S),fire,fallingobjects,trippinghazardsandnoise.Minimisingriskwasaprominentfeatureofeverytoolboxandpre-tasktalk,andwasbrokendowninto

twocategories:generalsitesafetyandtask-specific.What’smore,allstaff–notjustthesafetyofficers–playedapartinensuringthateveryoneoperatedwithgoodsafetypracticesforemostintheirminds.

Despitefacingnumerouschallenges,AJHLnotchedupanumberofoutstandingachievementsonthisproject.InadditiontozeroLTIandalwaysbeingreadyaheadofschedule,AJHLwasawardedaSilverSafetyHelmetforitsexcellentsafetypracticesthroughoutitstimespentworkingontheproject,andfortheteam’soverallcontributiontoasafeworkingenvironment.

Onceagain,AJHLdemonstratesithastheprofessionalism,teamworkandwealthofexperiencetosuccessfullycompletetheworld’smostdemandingtransportationandheavyliftoperations.

AJHL was awarded a Silver Safety Helmet for good safety practices on the project


WorkontheUAE’siconic1,200km-longrailtrackiswellunderway.Thefirststageisa270km-longfreightlinelinking

RuwaistotheShahgasfield.Layingmetreaftermetreofhigh-precisiontrackisjustonevitalelementofthisenormousproject;anotherisactuallyinstallingthetrainsontothetracks.

Ataskofthisscalerequiresnotonlyheavyliftcapability,butexceptionalattentiontodetail.

TheclientawardedAJHLtheheftytaskoftransportingandliftingeight,fullybuilt-uplocomotives.Weighing185Teeachandmeasuring22.88mby3.23mby5.21m,thelocomotivesneededtobetransportedfromtheMusaffahGovernmentjettytoMirfa,beforefinallybeinginstalledontotherails.

AJHL’sjobwastoreceivethelocomotivesontoaconventionalmodulartrailer,jackdownonstoolsforcustomsclearanceatMusaffahport,thentransportthemtoMirfasite,againusingaconventionalmodulartrailer.

OnceatMirfa,AJHLwoulduse450Te/500Tecrawlercranestoliftthelocomotivesontotherails.

AJHL takes the strain on one of the Middle East’s most prestigious projects of the moment: the UAE’s national railway network

on track for success

Theeightlocomotivesweredeliveredinthreeshipments:thefirstcontainingasinglelocomotive,thesecondtwolocomotives,whiletheremaininglocomotivesarrivedinthethirdshipment.

Theentireprojectrequiredrigorousplanningwithdetailedengineeringandriggingdesignstrategies.Thepre-engineeringphaseincludedthepreparationofworkpackscontainingtheprojectexecutionplan,riggingandtransportstudies,methodstatementandriskanalysis,aswellasthenecessarycertificationsofequipmentandpersonnelinvolved.

Ateamofapproximately15employeesweremobilisedattheMirfasite,includingaprojectmanager,engineer,transportsupervisor,liftingsuperintendent,operators,driversandassistcrew.

Effectivecommunicationwasachievedviaamasstoolboxtalkconductedeveryday,inadditiontopre-tasktalks,carriedoutbeforeeveryoperation.Aswithalltime-sensitivejobs,planningandcommunicationwascritical.Tokeeptheclientupdated,carefulcoordinationandcooperationwasestablishedfromtheoutsetandhelpedmakethisprojectaresoundingsuccess.

Lifting duties

Whenitcametoliftingduties,AJHLutilisedaDemagCC2500-1(500Tecapacitycrawlercrane)tocarryoutoperationsatsiteforthefirstshipmentoflocomotives,whileaDemagCC2500(450Tecapacitycrawler)wasusedfortheremainingshipmentoflocomotives.

Fortransportingthelocomotives,AJHLutilisedComettoconventionalmodulartrailersin15axlesside-by-sideconfiguration.Drawingsfromtheclientdetailingthelocomotives’weight,dimensions,centreofgravityandsaddleslocationwerevitalforourengineerstodeveloptheirowntransportationstudiesanddrawings–inadditiontokeepingwithinstrictlimitationsassetoutbygovernmentbodies.

Additionalkeyinformationsuchasthelocomotives’liftingpoints,aswellassiteconditionsandtherequiredradiusinordertoestablishsuitablecraneandotherliftingaccessoriesalsoprovedvitaltothesafecompletionoftheproject.

in safe hands

AchievingAJHL’sprimarytargetofthesafe,on-timedeliveryofthelocomotivesmeantundertakingathoroughriskassessment.Thisidentifiedtotheclientanysignificantriskactivities,highlightedthemeasuresinplacetocontroltherisk,andjustifiedwhethertheexistingcontrolmeasureswereadequate(andifnot,providedadetailedplanofactiononhowtheriskcouldbecontrolled).

AJHL’sinvolvementinthisstageisanexcellentexampleofhowearlyinvolvement,teamwork,ameticulousapproachtosafetyandoperations,alongwithanin-depthunderstandingoftheclient’sneedsandoperationalrequirementscanmakeitpossibletoachievethetargetsuccessfully,safelyandontime.

UnderstandingandsupportingclientsthroughprofessionalcontactandassistancethroughoutaprojectisakeyAJHLcharacteristic.Thecoordinatedteamworkmadethelogisticalchallengeofsafelyhandlinglocomotives,asuccessfulreality.Withareputationforthehighestqualityheavyliftingandheavytransportationprojects,AJHLisproudtoofferitsindustryexpertisewithintheUAEtohelpshapethefutureofthecountry’snationalrailnetwork.

Getting the show on the road: A task of this scale requires not only heavy lift capacity, but exceptional attention to detail


Becominganaccomplishedcraneoperatorrequiresskill,dexterityandplentyofpractice.That’swhyAJHLhasinvestedinstate-of-

the-artsimulatorssotraineescanlearnthebasicprinciplesofoperatingacranesafelybeforehandlingtherealthing.

Usingheavy-equipmentsimulators,traineeoperatorsbenefitfromimmersiveenvironmentswhichhelptodevelopessentialskills,increasesafetyandreduceoveralltrainingcosts.What’smore,thereisnodangertoequipmentorpeoplewhenusingthesimulator.

hi-tech tRaining

Developedinconjunctionwithoperators,trainersandsimulationexperts,thesimulatorsdeliveranintegraltrainingsolutiontohelpprepareheavyequipmentoperatorsforthechallengesahead.

Instructorscanloadmultipleworksiteaspectsonthesimulators,andtrainnovicesthroughtoadvancedstudentsinawiderangeofworkconditionsandtests.

Inadditiontogainingabasicknowledgeofthesystem,traineeslearnaboutdifferentsettings,howtochecksafetysystemsandhowtotroubleshootelectronicdefaults.

Allsimulatorsprovidestunningrealismthroughlife-like3Dvisuals,authenticmachinesounds,high-fidelityequipmentdynamicsandenvironmentaleffects,andrealmachinecontrolssuchasjoystickcontrolleverandloadmomentindicators.

siMuLatoR success

Asheavyliftcranesarecomplexmachines,dangeroustooperate,expensivetorunandnotalwaysavailablefortrainingpurposes,thesimulatorsofferclearadvantages,justifyingAJHL’sinvestmentinthesophisticatedtrainingequipment.

tRaining for the top

Safety is paramount, which is why AJHL invests in the latest technology to ensure its staff receives the most advanced training

MohammadAnwarisamanwhoknowswhatittakestogetajobdone.OriginallyfromPakistan,hejoinedAJHLmorethanthreedecadesago

andisanintegralpartofitssuccessfulgrowthhistory.Fromsmallbeginnings,Anwarhasworkedhiswayup

thecareerladder,provingheistrustworthyandreliable.WithaworkingknowledgeofspokenArabic,English,FarsiandUrdu,AnwarhasundertakennumerouscomplexheavyliftprojectsforAJHLworldwide,fromacrosstheGCCtoPakistanandMalaysia.Inadditiontobeingakeyteamplayer,motivatorandleader,Anwarishighlyregardedbyclientsthankstohissafeandsuccessfulprojectdeliveryrecord.

Anwar’slongservicewithinAJHLmeansheiswellacquaintedwiththecompanyprojectdocumentationandprocedures.Heisafineexampleofhowthecompany’scomplexliftingoperationsareundertakenbythemostexperiencedpeople,whosetechnicalexpertiseandcommitmentguaranteesthequalityofAJHL’sservice.

With a career spanning over 30 years at AJHL, Heavy Lift Superintendent Mohammad Anwar is a key team member

on duty

edition 5 highlights 22


Please visit our website (www.ajhl.com) for subsidiary branch contact details and other information.

CorporatE oFFiCE

al JaBEr HEaVy liFt Mussafah, uAETel: + 971 2 555 4300Fax: + 971 2 555 3370Email: [email protected]

doHa HuB

al JaBEr HEaVy liFt & traNsport wllP.O. Box 40032Doha, QatarTel: + 974 4460 3899Fax: + 974 4460 3897Email: [email protected]

aBu dHaBi HuB

al JaBEr HEaVy liFt & traNsport llCP.O. Box 2175Abu Dhabi, uAETel: + 971 2 582 5454Fax: + 971 2 582 5115Email: [email protected]

siNGaporE HuB

al JaBEr HEaVy liFt & traNsport ptE ltd21 Pandan crescentSingapore 128471Tel: + 65 6775 2411Fax: + 65 6778 0026Email: [email protected]

highlights edition 5

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