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Mammoet helped reinstall Orion's crane

By: Tom Russell 16/05/2022 Mammoet

General Vessels

DEME Group's new heavy lift crane vessel Orion has seen the reinstallation of its Liebherr HLC 295000 crane. It will be used in the construction of modern offshore wind turbines.

Mammoet secured a contract for all transport and lifting activities associated with rebuilding the crane. The dimensions of the HLC 295000 components included a slewing unit weighing 1,850t, a boom of 1,500t and 120m long, with an A-frame weighing 900t and 70m long.

To handle these items safely, Mammoet needed to deliver around 2,000t of material to the site. This included various cranes, transport vehicles, 400t of rigging equipment, as well as support and special equipment.

The plan created by Mammoet’s engineering team was included a custom transport and lifting concept using Liebherr's own TCC 78000 rail-mounted heavy-duty crane. The plan would also use two crawler cranes, several mobile cranes and Mammoet's JS 500 jacking system.

Special rigging schemes were designed and fabricated to meet the specific component requirements. In order to maneuver the oversized and heavy components safely across the Liebherr site, the transports were planned with 68 axle line SPMTs.

First, the slewing unit was transported from the pre-assembly site to the crane location. It was lifted and installed onto the offshore vessel in a tandem lift using the TCC 78000 and an LR 11350.

In a second operation, the A-frame was erected via a tandem lift using the TCC 78000 and an LR 1750. The component was transported approx. 800m on the hook of the TCC 78000 and lifted to a height of 120m, onto Orion , for installation.

Finally, the boom was lifted onto Orion in a tandem lift using the TCC 78000 and a LR 1750 to a height of approximately 60m and installed. The LR 1750 crawler crane, which had previously been used to tail the A-frame, was moved from the pre-assembly site to the quay within a and reconfigured to "luffing jib mode" for the boom lift.

"Execution in autumn and winter always brings special challenges for projects of this type. The frequent occurrence of storms was closely monitored by permanently checking and previewing the weather conditions. Thus, even the smallest wind windows could be exploited to safely realize partial activities within the specified time. Even the start of the lifting activities as early as 4 a.m. in the morning posed no obstacle", explained Gernot Öder, Manager Crane and Transport Projects Engineering & Project Management.

The restored crane’s first project will be Arcadis Ost 1 offshore wind farm in the Baltic Sea and further deployments are already planned.

The crane was originally installed back in February 2020 however in May 2022, during a load test whilst berthed at Liebherr's facility in Rostock, it collapsed.

Orion was constructed at COSCO Qidong shipyard in China. At 216.5m long, it is equipped with DP3 (Dynamic Positioning) capability and can accommodate a total of 131 people. The vessel is also to be outfitted with a Walk-to-Work gangway for personnel transfers.

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Mammoet helped reinstall Orion's crane

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