Professional Documents
Culture Documents
A General
1 Foreword from CEO 2
2 About ElectroMech & Cranedge 3
3 Introduction to Manual 5
4 General description of cranes 6
E Standard Drawings 40
We envisage ElectroMech becoming a worldwide brand leader in its field of operations by consistently
delivering world-class quality products in the lowest possible lead times at the most competitive rates.
True to this vision, ElectroMech, over its history of operations, has shown consistent improvement in
performance by delivering top-class products and by catering to a wide range of client requirements. Be
it the case of supplying mass-customized hoisting applications for a multi-million dollar, multinational
power project, or of supplying specialized material handling equipment to various infrastructure
projects funded by the World Bank, ElectroMech has made its own contribution towards the
successful commissioning of such projects.
In the Indian industry today, ElectroMech has become a name to be reckoned with when it comes to
engineering of customized material handling solutions to suit complex customer requirements.
We, at ElectroMech, have a strong tradition of innovation and we are constantly engaged in upgrading
our products to match the current world-class standards. Unique business processes that have evolved
in-house through continuous improvement exercise ensure the high quality of products and timeliness
of deliveries. We are proud of the fact that we have set quite a few benchmarks for our competitors to
emulate.
Today, ElectroMech ranks among one of the premier manufacturers of Cranes and Hoists in India and
the vision of the management is to extend this reputation to the global stage. We thank you for
considering ElectroMech for your material handling requirements.
A V R Murty
CEO
Electromech
3 General 2. About ElectroMech & Cranedge
2.1 ElectroMech
As an ambitious company that is bent on attaining the leadership position in the material handling
industry globally, we, at ElectroMech, are always doing something newer and more exciting. Thus, it
gives me pleasure to introduce one more issue of our newsletter, EMPOWER that chronicles the latest at
ElectroMech.
Considering the long-term growth plans of ElectroMech and to ensure proper funding for this growth,
ElectroMech took on an exciting move of inducing Private Equity investment in the company. This paves
our way to pursue exciting growth opportunities involving strategic investments, consolidations and
new product introductions. India is all set to reach the figure of USD 5 Trillion in GDP by 2020 from the
level of approximately USD 1.5 Trillion currently. This massive growth, expected to happen in the
compressed time frame spread over the next decade, throws up a lot of exciting challenges. We, at
ElectroMech, believe that this is a once-in-several-centuries opportunity that needs to be tapped
properly as this opportunity is never going to come up again. Hence, having the right financial partner
with us helps us in making our foundations stronger and fuels our growth plans.
This issue also talks about the two latest tie-ups we have entered into - Sibcranex of Russia and
Shuttlelift of USA. This could have been considered to be a political coup in the eighties as getting
Russian and American collaborations for the same company was quite unlikely. However, the world has
changed for the better and India is the place where the action is.
Through Sibcranex, we aim at participating in the growth set to unfold in the Indian steel industry
where more than 100 Mn MT of annual steel producing capacity is estimated to be set up in the next
decade.
Through Shuttlelift, we are introducing an exciting new product - Rubber Tyred Gantry cranes for
industrial applications. We believe that this product can revolutionize the way bulky items are handled
at sites and improve productivity and enhance safety of men and material
We are proud to be associated with several prestigious infrastructure projects like coal power plants,
water supply, sewage, nuclear power plants and renewable energy. This issue shares with you some
details of the projects that we have been associated with.
Technical leadership is something that is not developed overnight. The Stahl Ex range of products is a
perfect example of this. Being in existence since 1920s, the Ex range of products from Stahl continues
to dominate the global market technologically. We have an interesting write-up in this issue showcasing
Stahl Ex's technical prowess.
Our services subsidiary, Cranedge continues to cover newer ground every passing day. In this issue, we
are proud to share with you the way Cranedge helped one of our esteemed customers derive maximum
ROI by refurbishing old equipment and enhancing productivity and safety.
General 2. About ElectroMech & Cranedge 4
2.2 Cranedge
Cranedge India Pvt. Ltd. is a company initiated by ElectroMech. At Cranedge, we have access to the rich
knowledge of ElectroMech built painstakingly over more than 30 years and spread over a few thousand
installations. Also, we have quick access to ElectroMech databank, spares inventory and manufacturing
facilities. This makes Cranedge a knowledgeable and resourceful organization which will always benefit
our customers. This company is exclusively engaged in providing after-sales-service to users of
overhead cranes. These services are made available through a team of well-trained and skilled
engineers and technicians.
The manufacturing industry employs several advanced material handling systems, where EOT cranes
play a pivotal role in efficient material handling. Plant productivity is greatly dependent on 24x7
availability of such cranes. Hence, periodic crane maintenance is a key to productivity. In some plants,
several cranes are used. They vary not only in type and capacity, but are installed at different times. In
some cases, even the makes of these cranes are different.
This poses a challenge for the maintenance department of the user company. The option could be,
either to train their own manpower for different makes and different types of crane maintenance and
also maintain spares inventory for each of the cranes, or alternatively hire maintenance services of the
individual supplier companies which may not be available or reliable in all cases.
Some companies also tend to opt for the services from local maintenance companies.
This manual is prepared for providing our clients with comprehensive directions for erection, operation
and maintenance of the cranes supplied. Do take care to place this manual in the hands of the right
individual, the mechanic and the operator who actually attend to the maintenance work and operation
of the crane.
Read all the detailed information available in the manual before putting the crane into
operation
Important Note:
It is the responsibility of the owner / factory in-charge to ensure that all personnel operating and
maintaining this equipment are properly trained. No one should be permitted to operate or maintain
this equipment until they have received such training and become fully acquainted with the relevant
operating and maintenance instructions in this manual.
General 4. General description of cranes 6
EOT cranes travel on a pair of gantry rails mounted on gantry girders, which in turn, are supported on
columns on two sides of the bay. The crane consists of bridge girders, end carriages, platform, trolley
assembly and long travel drive machinery. Machineries for the hoisting motion and trolley travel
(traverse motion) are mounted on the trolley, which moves on rails fixed on the top of bridge girders.
These cranes find their applications in a wide range of industries. Depending upon the needs specified
by the customer in enquiry, the cranes are supplied with special features such as -
Ø All motions, with in-built DC disc brakes Ø Top and bottom limit switches
(rotary / gravity)
Ø Hardened and ground helical gears that provide
high efficiency, quiet and long lasting operation Ø Hoist motors with minimum 40 CDF and
150 starts / hour
Ø All electrical connections of plug socket type Ø Soft start / soft stop through inventors
Ø All wheels with direct drives Ø Twin cross travel drives
Ø No open gears on any travel motions Ø Low crane headroom
Ø Maintenance platform Ø Anti collision device
Ø Load display indicator,
In EOT cranes, 3 common motions are incorporated; namely Hoisting, Cross Traverse and Long Travel.
Sometimes, according to the customer's requirements, Auxiliary Hoisting and Micro Motions are also
incorporated. Hoist and CT machineries are fitted on a common frame known as a crab in case of a
double girder crane, whereas they are a part and parcel of the Electric Hoist itself in case of a single
girder crane.
4.3.5 Platforms
Access platforms are provided for easy access to the operator’s cabin,
electrical panels and for maintenance of long travel machinery. Toe
guards and hand rails are provided on the platform for the safety of
operating personnel. The platform may also support fixtures for under
bridge lights. Generally, separate platforms are provided for supporting
foot mounted long travel drive mechanism. Access ladders may be
provided from girder/end carriage to the platform depending upon
geometry.
4.3.9 Pendant
The operation of the crane is generally through a pendant push
button section. The pendant gives the crane operator precise control
over the motions of the crane. There are many configurations of the
pendant depending on the functions of the equipment being
controlled. Each push button on the pendant controls an operating
function of the crane.
General 4. General description of cranes 10
There are 8 push buttons on the pendant. They are Hoisting Up, Hoisting Down, CT Right, CT Left, LT
Forward, LT, Reverse, Start and Emergency Stop. The pendant may be suspended from the Trolley
Hoist, requiring the operator to walk with and beside the load, or on a separate sliding track system
allowing the operator to move independently of the load.
For CT (Cross Travelling) motion & LT (Long Travelling) motion CT & LT master controllers are used.
Four speeds are achieved by moving the lever of Master Controller step by step (1-2-3-4). The contacts
are closed respectively. The same functions in the opposite direction result in opposite motion with 4
speeds & vice versa.
of slip ring induction motors is it has high starting torque when compared to squirrel cage induction
motors. Approximately 200 - 250% of its full-load torque. However, speeds cannot be adjusted. Slip
ring motors come with external resistance.
4.3.20 Contactors
A contactor is an electrically controlled switch used for switching a power circuit. Contactors typically
have multiple contacts, and those contacts are usually (but not always) normally open, so that power to
the load is shut off when the coil is de-energized. Perhaps the most common industrial use for
contactors is the control of electric motors.
13 General 4. General description of cranes
relay
A
3-phase motor
B
AC power
C
120 VAC
coil
5.1
A proper alignment of gantry rails plays a very significant role in long and trouble the free service and
safety of crane. Poorly maintained tracks reduce the service life of rails and wheels. They also have a
detrimental effect of poor conditions of rail tracks on hoisting appliances. It is so great, both for the
structures and machineries, that no shock loading co-efficient can compensate the damage caused by
poor alignment / maintenance of rail joints specially in case of high speed cranes.
5.2 Dimensional and geometric tolerances of tracks for overhead and under
slung cranes.
5.2.1 General
Tracks should be within the tolerances given in clause no.s 5.2.2 to 5.2.6. The measurement should be
done when the tracks are not supporting the crane.
5M
10 M
10 M
5M
5M
SPAN
-+ S
H
W-
-+
+
W S = =
SPAN
Underslung cranes
Tolerance on span level differences and track width for gantry rails
Fig. 5.2
Crane erection &
commissioning 5. Instructions for gantry rail alignment 16
Straight line
Mean datum
10
2000
1
L
L/2000
10
The straight line mean datum is the line about which deviations of track on each side will be equal, when
summated over the whole length of the track.
Local lateral deviation at any point of the track should not be greater than L/2000, measured over a
length of not less than 2 meters on a line parallel to the straight line mean datum.
Theoretical datum
2000
10
1
10
L/2000
L
Local vertical deviation at any point of the track should not be greater than L/2000. Measured over a
length of not less than 2 meters on a line parallel to the theoretical datum.
5.2.6 Running surface permissible traverse inclination from the horizontal datum position.
The maximum permissible traverse inclination from the horizontal datum position should be as shown
in figure 5.5
0
_ 1 IN 30
_< 1
<
IN
300
DATUM POSITION
FIG. 5.4
5.4
It is assembled that the gantry girders, columns & foundations are designed in such a fashion that with trolley
positioned in the centre of the span, the deflection of both gantry rails tracks is approximately equal.
Crane erection &
commissioning 6. Instructions for alignment of Down Shop Leads (power angles) 18
6.1
Proper alignment of Down Shop Leads (DSL) play an important role in trouble-free operation of the
crane. Poorly maintained DSL leads to short circuiting / single phasing due to falling of current
collectors.
6.2.2 Tolerance on distance between center line of gantry rail to datum line of DSL.
The tolerance on the above should be as follows.
S 5 mm
2000
exceed 10 mm (see fig 6.3). The
4
L
horizontal line.
L/500
The crane and its components are dispatched to the site by road / rail / sea route in suitable packing and
protection against damage during transit is ensured to the maximum extent. However, during storage
at site for long periods, special precautions are to be taken to eliminate the possible deterioration and
exposure to elements of nature.
ElectroMech method of crane dispatch
b. Miscellaneous Items - Other mechanical items like Lower Block, Wire Ropes, Shafts, Couplings,
etc. which are dispatched in closed cases should be stored in covered storage area. All fasteners
including machined bolts should be kept properly oiled.
7.3 Electricals
All electrical items like operator's cabin, panel boxes, resistance boxes, pendants, cables, etc., should
be stored only in closed area. In no case should these items be stored in vertical position and the cases
containing the panels and resistances should also be stored in vertical position.
7.4 General
a. If the materials have been lying for a long time at the site, it is necessary to do the following
before the commencement of erections.
b. No load running trial of all mechanisms.
c. Insulation test of all electrical components like motors, brakes, limit switches, panels,
resistances, controllers, etc.
d. To check the condition of grease in wheel assemblies for crane and trolley and to ensure that
these move freely.
e. To check the lubrication in pulleys, couplings, etc.
f. To check the gear boxes through inspection covers.
g. In case the storage area is easily susceptible to pilferage, all electrical components like motors,
brakes, limit switches, etc. may be dismantled from assembly and stored separately in a safe
location or inside the store. Also, in case of indoor storage, the area may be cordoned off and
should be located away from the main handling area.
7.5 List of standard equipment tools and tackles required at the time of
Erection and commissioning of crane.
a. Multi-meter h. Line tester n. Hammer
b. Piano wire i. Screw driver set o. Safety belt
c. Measuring tape j. Cutting pliers p. Safety shoes
d. Deflection meter k. Combination pliers q. Safety helmet
e. Spanner set l. Wire stripper r. Fire extinguisher
f. Arc welding machine m. Torque wrench s. First aid box
g. Arc welding rod
Statutory Requirement: "As per Factories Act 1948 (Section 29), it is mandatory to test the crane in presence of
a competent person after the crane installation & subsequently at least once in twelve months and records of
testing must be maintained"
Hence, the customer is to arrange for a competent person to witness the Load Testing during crane erection to
avoid re-arranging for load testing separately.
Crane erection &
21
commissioning 8. Standard procedure for erection of EOT cranes
5. Lift the girder with suitable slings with the help of suitable mobile crane in balanced condition
and place it on the crane track.
6. Remove the mobile crane after placing the girder on the crane track.
7. Proceed with the crane free running on the entire bay length area to ensure trouble free
movement of the crane on the tracks.
8. Install the LT motors and other accessories after the crane free running.
9. Proceed with crane wiring and commissioning.
mobile crane
9. Hold the rigid leg with the mobile crane; put the stopper on both sides of rigid leg end carriage
10. Repeat the process from points 7 to 9 for flexible leg with suitable crane
11. Lift one main girder with suitable nylon slings with the help of suitable mobile crane in balanced
condition
12. Put that main girder as per match marking given on girder joining (which has to be decided on
site as per site situation) between rigid leg & flexible leg
13. Bolt the girder between flexible & rigid leg with given fasteners with torque mentioned in GA
Drawing
Before commissioning the crane, carry out the following checks to ensure that the crane is ready for
peration.
9.1.1 Check physical dimensions / tolerances such as span, diagonal, skew, etc. of the crane & ensure that
they are within acceptable limits as given in chapter 16 of this manual.
9.1.2 Carry out insulation test of motors with 1000 V megger. The megger value should be minimum 50 mega
ohms (during monsoon a lower merger value of 2 mega ohms should be ensured). Improve merger
value if necessary.
9.1.3 Check DSL insulation value. Ensure that the supply voltage is within ± 6% of rated voltage at DSL.
9.1.4 Fill up oil in gearboxes as per the marking on the dipstick.
9.1.5 Check functioning of Group / Centralized lubrication systems. Grease various points using lubricating
system / grease gun. Grease the thrust bearing provided in the hook block.
9.1.6 Apply lubricant to the wire rope.
9.1.7 Fill up brake oil in the thruster brakes.
9.1.8 Give supply to control transformer, check all sequences of control panel.
9.1.9 Give power to the crane & carry out power test on panels. At this time, de-couple the motors from
gearboxes & direction of rotation.
9.1.10 Set all limit switches & brakes.
9.1.11 Install buffer, buffer stoppers & actuators for limit switches.
9.1.12 Check setting of timers for smooth operation.
Load Test
a) Raise a load equal to about 100 % of the rated load not higher than required to clear its
supports/ stop and adjust the brake, if necessary, raise load about 1 m above its supports and
stop. Lower the load about 300mm and stop. Check drift of load during stopping. If load slips, it
indicates that brakes are not properly adjusted and should be corrected. Repeat this operation
until proper adjustment of brakes is obtained. Lower load carefully back to its supports.
Crane erection &
25
commissioning 9. Standard procedure for commissioning of EOT cranes
b) Then hoist the load high enough to clear all obstructions but not higher than necessary. Move
trolley across the entire span of bridge. Transport the test load by means of the bridge for full
length of the runway in one direction with the trolley at the extreme right hand end of the crane
and then move in the other direction with the trolley at the extreme left hand end of the crane.
c) Measure the deflection when the trolley with 100% of SWL is at the middle of the girder and at
extreme end of the girder. Check whether the deflection is within the allowable limit.
d) Measure the full load current of the motor and verify whether it is as per the recommendations
of motor manufacturers.
proper slinging locations and arrangements to carry the test by crane hook, & the slings must have test
certificates before taking test.
Deflection Test:
9.4.1 Crane to be moved to the location, so that it can be just above shop columns. This will avoid the
deflection of gantry girders (if any)
9.4.2 Crab hoist will be moved in CT motion to its extreme end of the crane span with smaller hook approach
to achieve the datum line of the reading.
9.4.3 First reading 'H' is to be taken at the girder bottom. This will be measured with the help of deflect meter
(laser type).
9.4.4 Move crab/hoist to the central position of crane span. Lower the hook to extreme bottom position &
connect the load with the help of slings to crane hook.
9.4.5 Now load this particular load which is exactly that of SWL capacity with 'UP' motion of the crane hook.
9.4.6 Allow the load to come to its stable condition (girder shall be allowed to come to its stable position after
oscillations due to lifting of the load)
9.4.7 Measure the second reading 'h' on the girder bottom with the help of deflect meter.
9.4.8 Deflection (∂) of the girder is nothing but subtraction of reading above mentioned readings.
i.e. ∂ = 'H'- 'h'
9.4.9 As per clause 7.4.1 of IS 807, vertical deflection caused by SWL & crab/hoist in the central position
(without taking into consideration of impact factor) is SPAN/900.
NOTE : Please note that measurements shall not be taken on the first application of the load.
27 10
Safe Operation
10. Instructions for Safe Operations of EOT Cranes
Of Crane
6. Move slowly 7. Move towards 8. Move towards 9. Swing towards the 10. Swing towards
by indicating the hand stretched the hand stretched hand stretched the hand stretched
distance direction direction direction direction
11. Raise the boom 12. Raise the boom 13. Lower the boom 14. Lower the boom 15. Raise the boom
slowly slowly & lower the load
16. Lower the boom 17. Extent the boom 18. Retract the boom 19. Use the main 20. Use whip line
& raise the load hoist
21. Lower the hoist 22. Lower the hoist 23. Raise the hoist 24. Raise the hoist 25. Stop every thing
slowly slowly
Contd…..
Safe Operation
Of Crane 10. Instructions for safe operations of EOT sranes 28
10.1.1 Check the crane and crane way for any obstructions.
10.1.2 Release all locking devices.
10.1.3 Check that parts needing lubrication have required quantity of lubricants.
10.1.4 Ensure that no item is lying loose on the crane and the trolley.
10.1.5 Check for neutral position of all the control gears.
10.1.6 Switch on the crane protective gear.
10.1.7 Check signal and wiring devices.
10.1.8 Check brakes and limit switches for their proper functioning.
Ø Do not load beyond the rated capacity. The immediate danger is possible failure of some load
carrying part. Overloading might also develop a defect which could lead to some future failure,
even at less than rated capacity.
Ø Do not use any overhead material handling equipment for the purpose of transportation of
personnel.
Ø Conduct a periodic visual inspection for signs of damage or wear. Particular attention should be
paid to the wire rope and the hook. If there are signs of wear or damage, or if the hook is
distorted or opened out, immediately intimate safety engineers before loading.
Ø Do not use hoisting ropes or chains as a substitute for slings. Always use slings. Cable / chain /
belt / rope slings should be of proper size and type for load handling. Never use slings showing
physical damage to any extent.
Ø Stand clear of all loads. If you must travel a load over the heads of other personnel, give ample
warning of your intention before you move.
29 10
Safe Operation
10. Instructions for Safe Operations of EOT Cranes
Of Crane
Ø Always 'inch' the hoist into the load. Running into the load at full hoisting speed imposes an
excessive overload on the hoisting mechanism and could result in the failure of parts and / or the
supporting structure. This is particularly true with high hoisting speeds. The same principle
applies to the travelling motion also, which would otherwise cause a swinging of the load leading
to unforeseen damages.
Ø Limit switches are for emergency use only. They should not be tripped during normal
operations. If it is necessary to travel to the limit, use extreme caution and approach the limit in
slow speed or by inching. Do not leave the hook block in contact with the limit switch at the end
of the operation. A phase reversal with the block in this position will probably result in damage to
the hoist of the Down button or control lever is operated.
Ø Be sure that the hoist raises and lowers properly when the corresponding push button or control
lever is operated. A reversal of direction indicates a phase reversal in the current conductor, or
an interchange of wires on the push button, any of which would cause the limit switch to be
inoperative. Do not, under any circumstances, operate the equipment until the fault has been
found and corrected.
Ø Center the hoist over the load before lifting. Do not side pull or end pull. When the centre of
gravity is difficult to determine, the load must be raised a little at a time to see that each part
leaves the ground at the same time. The use of many ropes would be meaningless if the load is
not supported evenly.
Ø Use padding on the edge of load if it is sharp and angular. This prevents the damage of the rope.
Contact of the wire rope with a sharp angular edge of the load is unsafe. The wire rope can be
cut very easily when it is twisted. Remember that twisting and pulling is the method employed
when it is necessary to cut the wire rope.
Ø The limit of the straddle angle of the sling should be kept within 90o. Else a larger load than
commonly supposed works on the wire ropes.
Ø Wire ropes for load handling should not be placed on the portion of the load that may cause
them to move or slip off.
Ø Reversing the positions of an object or load is very dangerous. This operation should be done
very slowly taking care that the ropes do not become loose. When the ropes become loose, the
next thing to expect is a sudden reversal of the object. This will cause a very heavy strain on the
ropes and possibly make them snap.
Ø Do not drag the load. It is dangerous to assume that a load which has been safely tied can be
dragged, because dragging the load creates higher stress in the wire rope than when
suspending it.
Ø Proper knowledge of hand signals for hoisting, cross travel and long travel is imperative, if
working with a cabin operated crane. Operators should accept the signals of only those persons
authorized to give them. Do not, repeat, do not operate when the signals are not clear.
Ø Do not leave the load suspended in the air unattended.
Ø Do not jog controls unnecessarily. Hoist motors are generally of high torque, high slip type. Each
start causes an inrush of current greater than the running current and leads to overheating and
subsequent failure due to heat or burnout, if continued to an excess.
Ø When the crane is operated after a long period of disuse, be sure to operate all the motions
without load first.
Safe Operation
Of Crane 10. Instructions for Safe Operations of EOT Cranes 30
Ø Only trained, competent and properly authorized crane drivers are permitted to operate
overhead travelling cranes. A crane driver must have a written knowledge of English.
Ø Crane drivers must be physically fit, and have good hearing and eye sight. A crane driver shall
not operate his crane if not physically fit, but shall report any disability to the medical officer or
other appropriate person at once.
Ø Crane drivers are expected to be extremely alert at all times. Sleeping on the job, throwing
ashes or cigarette butts or spitting from the control cabin or bridge structure are not to be
permitted under any circumstances.
Ø They must keep their hands free when going up or down the access ladders.
Ø Their spare clothing or any personal belongings should not be kept in the vicinity of the controls.
Ø The operators must be fully aware of the crane safety, operating instructions, crane mechanism
and its proper care.
Ø Extreme care shall be exercised at all times by the crane drivers and attendants, and all other
personnel working or present on the premises where cranes are located, to avoid contact with
the crane collector wires and / or any other power cables, whether covered or bare.
Ø Rail trucks, cars, or any other transport vehicles should not be towed by any crane.
Ø The crane driver must ensure that the fire extinguisher is kept in an accessible position and fully
ready for use.
Ø The communication between the crane driver and crane attendant (slingers), shall be through
mutually agreed code of hand signals / radio device. Verbal instructions can be given only if they
are rendered audible.
Ø The crane driver should maintain a log book and make the appropriate entries in it on a daily
basis.
Ø The crane driver is at all times responsible for the safe operation of the crane.
Ø He should at all times ensure that the crane is properly lubricated in accordance with the
instructions issued.
Ø He should not leave the controls while a load is suspended from the crane.
Ø He should not permit anyone to be in any position on the crane, during normal operation of the
crane.
Ø If and when any crane operation fails to respond correctly to the control, the crane driver must
immediately stop operation and open the power switch and notify the supervisor. No attempt
should be made to get out of difficulty by repeated operations of the controls.
Ø In case of power failure, the crane driver shall move all controllers to OFF position, report the
matter to the supervisor and await instructions.
Ø The crane driver should not rely on the limit switches in ordinary working, as they are for
emergency purposes only. The crane driver should not tamper with circuit breakers, limit
switches and / or any other safety devices.
Ø Before closing the main switches, all controllers must be in the OFF position.
Ø All crane movements, whilst loads are being handled, or maintenance or repair work done, shall
be governed absolutely by the standard operating signals, as given above, transmitted to the
crane driver by the person authorized to direct these movements.
Ø The crane driver should obey a STOP signal, regardless of who gives it.
Ø Under no conditions should any crane driver move a load unless he has clearly seen and
understood the given signal.
31 10
Safe Operation
10. Instructions for Safe Operations of EOT Cranes
Of Crane
Ø Where two cranes are operating in tandem, the driver of each crane shall take movement signals
only from the same person. Before such tandem operations, however, special instructions will
have to be issued by the engineer.
Ø Bumping into runway stops should be avoided.
Ø All load movements should be done smoothly without jerking or sudden stops.
Ø Under no circumstances shall the crane driver attempt to travel any load until that load has been
hoisted clear of all obstructions.
Ø While handling loads approaching maximum rated capacity, the crane driver should test the
hoist brakes after the first load has been lifted a few centimeters clear off the floor by placing the
controller in the off position. If the brakes do not hold, the load should be lowered at once and
the brakes must be adjusted.
Ø While the crane is in motion, crane drivers should keep their hands on the controls at all the
time.
Ø All loads should be carried or suspended at a maximum height of 2.5 meters, except above
machineries where it may be further increased.
Ø After the load has been landed, crane drivers should not move the crane until the hook has been
lowered and the crane attendant has either hooked up or removed the lifting equipment used.
Safe Operation
Of Crane 11. Crane Maintenance Guidelines 32
11.3 Hooks
Criteria for hook replacement
A worn or damaged hook must be permanently removed from service if
(a) The throat opening, measured at the narrowest point, has increased by more than 15% of the
original opening
(b) The hook has twisted more than 10° from the original plane of the hook
(c) The hook has lost 10% or more of its cross-sectional area
(d) The hook is cracked or otherwise defective
(e) Wear or damage exceeds any criteria specified by the manufacturer
33 10
Safe Operation
11. Crane Maintenance Guidelines
Of Crane
11.4.1 General
In order to maintain electrical machinery in good condition, prevent accidents and make their life long,
it is essential to carry out routine and periodical inspection and maintenance.
Depending upon the environmental and operating conditions the rate of deterioration of electrical
machinery varies. Thus, it is difficult to establish uniform standards for inspection of electrical
machinery.
11.4.3 The following parts have high rate of wear and hence should be considered as expendable.
• Contact piece of reversible master controller
• Contact piece of magnetic contactor for main circuit
• Auxiliary contact piece
• Carbon brush
• Brake lining
11.4.5 The following parts should be serviced when damaged to some extent
1. Slipring face of AC motor
2. Contact face of contactors
11.4.6 The following items are detrimental to the proper functioning of electrical machinery and require proper
attention.
1. Abnormal decrease in insulation resistance
2. Entry of water into the machinery
3. Accumulation of carbon powder, dust or dirt in the machinery having a possibility to cause
moisture absorption, deterioration of insulation or interference with ventilation
4. Badly imbalanced air gap of AC motor or collision of rotor with stator.
5. Loosening of lead or terminals
6. Abnormal drop of supply voltage / frequency
11.4.7 The following parts may cause trouble due to carelessness in use or due to poor maintenance; hence
these parts should be repaired or replaced.
1. Fused contact piece
2. Burnt out magnetic coil
Safe Operation
Of Crane 11. Crane Maintenance Guidelines 34
11.4.10 Motors
a) Insulation resistance
Insulation resistance of motors shows reasonably high value when the motor is new. With the time of
use it gradually decreases due to deterioration of insulating material, moisture absorption or
accumulation of dust or dirt. The rate and degree of such decrease in insulation resistance depend upon
environmental conditions.
Insulation resistance of the windings both between phases and to earth should be taken by means of a
1000V megger before the motor is put into service. The insulating resistance should not be lower than 2
mega ohms when the motor is cold. If it is lower due to moisture, it should be dried before full voltage is
applied to the motor terminals.
d) Bearing
All motors are fitted with antifriction bearings in bearing housings and are charged with grease. Grease
the bearings periodically. Also disassemble the bearings annually and after washing, refill it with high
quality grease.
Contactors and relays should be protected from dust and heat. Inspect and clean them frequently to
prevent leakage.
Contact pressure, stroke and gap contacts should be maintained properly.
Examine wear of contacts periodically and replace the contacts when excessive wear is observed.
11.4.17 Contactors
Before inspection, switch off the contactor and upstream fuse switch. Inspect the contactor terminal
first after two months of installation and then after every six months.
Alteration of contact arrangement (NO to NC and vice versa) adversely affects the contactor
performance. Also removal of unitized contacts from contactor affect performance of remaining
contacts. Hence, this should be avoided.
Do not get perturbed over tarnished, blackened or slightly pitted contactors. These are normal
phenomena.
Contactors can be cleaned by carbon tetra-chloride Do not use abrasives to clean the contacts. Hard
deposits on contact tips can be removed by blunt knife, however, deposits on contact bridges need not
to be removed.
Do not apply grease or petroleum jelly on contacts. If contacts are slightly welded, they can be
separated by a screw driver, if they are not easily separable by the above procedure, replace them.
Replace contacts when only 30% of original contact tip remains balance. Contacts should be replaced in
pairs of moving and fixed contacts. After replacement, operate the contactor a few times before putting
it back in operation.
Tighten arc chambers screws periodically. Do not use broken / damaged / cracked arc chambers and
coil. Replace it. Do not clean magnet with sharp / pointed object / file or sand paper as it upsets mating
of magnet faces. Clean magnet with lubricant / chamois lather.
The only parts that can be replaced in a contactor are contacts, arc chambers and coils. Other parts of
the contactor are designed for life. Finally, use only genuine spare parts to ensure safety.
37 10
Safe Operation
12. Activities to be done on EOT Crane During Preventive Maintenance
Of Crane
MECHANICAL
ELECTRICAL
1 Gravity limit Switch checking N.A.
MH
2 Motor connection checking MH N.A.
Brake / Thrustor operation
3 N.A.
checking MH
Rotory / up-down limit switch
4 N.A.
checking MH
5 Motor Current during AMC MH No Load / Part Load /
Full Load
6 Motor Winding Resistance MH
02 200 MOTOR
03 300 THRUSTOR BRAKE
04 400 LOWER BLOCK ASSEMBLY
05 500 UPPER BLOCK ASSEMBLY
06 600 EQUILISER PULLEY ASSEMBLY
07 700 PEDESTAL ASSEMBLY
08 800 M.H. LIMIT SWITCH (ROEARY GEARED TYPE)
09 900 COUNTER WT.LIMIT SWITCH FOR M.H.
10 1900 GEAR BOX
CT MACHINERY
11 2000 MOTOR
12 2100 THRUSTOR BRAKE
13 2200 CROSS TRAVEL LIMIT SWITCH R R TYPE
14 2300 CROSS TRAVEL WHEEL
15 2400 GEAR BOX
LT MACHINERY
16 2500 MOTOR
17 2600 THRUSTOR BRAKE
18 2700 LONG TRAVEL LIMIT SWITCH R R TYPE
19 2800 LONG TRAVEL WHEEL
20 2900 TROLLEY FRAME
CRANE MAJOR COMPONENT
21 3000 GIRDER
22 3100 END CARRIAGE/BOGIE
Note - TITLE
''To order any spares kindly mention the serial 23 3200 PENDANT PUSH BUTTON
G. A. FOR SPARES LIST 24 3300 CABLE TROLLEY
number and assembly part no. with sub part no.''
Example - For ordering hook bearing crane sr. 25 3400 RRC
no.-Assly part no.-Sub part no. DRG. NO. REVISION 26 3500 MAIN HOISTING WIRE ROPE
e.g. - Order no. - 2095 - 400 - 402 SHEET NO.
001 0 27 3700 ‘IGUS’ DRAG CHAIN
(Note: While ordering for any Spare Parts mention Crane Sr. No., Drawing No. & Part/s No.)
41 10
Standard
G. A. for spares list
drawings
02 200 MOTOR
03 300 THRUSTOR BRAKE
04 400 LOWER BLOCK ASSEMBLY
05 500 UPPER BLOCK ASSEMBLY
06 600 EQUILISER PULLEY ASSEMBLY
07 700 PEDESTAL ASSEMBLY
08 800 M.H. LIMIT SWITCH (ROEARY GEARED TYPE)
09 900 COUNTER WT.LIMIT SWITCH FOR M.H.
10 1000 GEAR BOX
11 1100 MOTOR
AUX. HOIST MACHINERY
20 2000 MOTOR
21 2100 THRUSTOR BRAKE
22 2200 CROSS TRAVEL LIMIT SWITCH R R TYPE
23 2300 CROSS TRAVEL WHEEL
24 2400 GEAR BOX
LT MACHINERY
25 2500 MOTOR
26 2600 THRUSTOR BRAKE
27 2700 LONG TRAVEL LIMIT SWITCH R R TYPE
28 2800 LONG TRAVEL WHEEL
29 2900 TROLLEY FRAME
CRANE MAJOR COMPONENT
30 3000 GIRDER
31 3100 END CARRIAGE/BOGIE
32 3200 PENDANT PUSH BUTTON
Note - TITLE
''To order any spares kindly mention the serial 33 3300 CABLE TROLLEY
G. A. FOR SPARES LIST 34 3400 RRC
number and assembly part no. with sub part no.''
Example - For ordering hook bearing crane sr. 35 3500 MAIN HOISTING WIRE ROPE
no.-Assly part no.-Sub part no. DRG. NO. REVISION 36 3600 AUX. HOISTING WIRE ROPE
e.g. - Order no. - 2095 - 400 - 402 SHEET NO.
001 0 37 3700 ‘IGUS’ DRAG CHAIN
(Note: While ordering for any Spare Parts mention Crane Sr. No., Drawing No. & Part/s No.)
Standard
M. H. Lower block assembly 42
drawings
WIRE ROPE
14 15
18
13
12
11
16
10
9
CL PIN
8
4
17
3
19
7
6 2
5
CL TRAVERSE
CL HOOK
NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.
6
5
7 3
4
CL
2
9
CL
PULLEY
1
CL
10
CL
NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.
02 SPACER 502
10.0 20.0 5.0 <6 +_ 0.3 < 1000 +_ 2.0
DRG. NO. 01 MOUNTING BLOCK 501
20.0 32.0 6.0 < 30 +_ 0.5 < 2000 +_ 3.0 REVISION
500
32.0 50.0 8.0 WELDING < 120 +_ 0.8 < 4000 +_ 4.0 SHEET NO. 1 0 NO. DESCRIPTION PART NO.
Standard
AUX. H. Lower block assembly 44
drawings
18 WIRE ROPE
13
12
11
14 15
10
9
CL PIN
8
16
17
7 3
CL TRAVERSE
6
2
5
CL HOOK
NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.
‘A’
3 1
2
9 3
13
12 4
8 5
10 11
6
14
‘A’
SECTION “A-A”
NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.
‘A’
3 1
2
9 3
13
12 4
8 5
10 11
6
14
‘A’
SECTION “A-A”
NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.
C
L
1
C PIN
L
4
2
NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.
C
L
1
C PIN
L
4
2
NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.
1
2
4
3
6
7
5
NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.
1
2
4
3
6
7
5
NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.
Upper Block
Grease Mobil XHP 222
Equalizer Pulley
Lower Block
Grease Mobil XHP 222
Equalizer Pulley
Annexure A : Lubrication Chart 53 52
Hoist Upper
Grease Mobil XHP 222
Block Pulley
Hoist Upper
Grease Mobil XHP 222
Block Pulley Hinge
Gear Pinion
Grease Mobil XHP 222
Bearing
LT Wheel Inside
Grease Mobil XHP 222
Bearing
Annexure A : Lubrication Chart 53 54
Golliath Crane
Brief List of Critical Spare Parts for ElectroMech make Electric Overhead Travelling Crane
4 Thrust Bearing 1
6 Rotor Pinion 1
7 Brake Shims 24
8 Rotor Shims 5
12 Thrust Bearing 1
14 Rotor Pinion 1
15 Brake Shims 24
16 Rotor Shims 5
19 Rectifier 2
Electrical
What Not To Do
What To Do
þ Handle the equipment by its structure, or by the devices provided for this purpose, or in its original
packing.
þ Store the equipment away from aggressive atmosphere (dust, humidity, etc.)
þ Make sure that the machine is always clean and protected from corrosion (lubricated....).
þ The equipment should be installed by a technician with the necessary competence.
þ Make sure the machine attaching structure is rigid.
þ Make sure that the safety rules are followed (harness, clearance of work areas, posting up of
instructions to be followed in the area...)
þ Neutralize power sources.
þ Comply with the distance between the trolley and the runway.
þ Replace any worn or defective element.
þ The equipment should be maintained regularly, following the instructions in the manual.
þ Regularly check the equipment.
þ Check that the assembly elements are correctly tightened.
þ The components should only be replaced by original parts that are compatible with the type of machine.
þ Before operation, check that the load is correctly fastened and slinged.
þ Make sure that the load is correctly balanced before moving it.
þ Pay attention to the centre of the load to be moved.
þ When moving the load, make sure that it is sufficiently raised and distant from the surrounding
machines and other objects so as to avoid all obstacles during operation.
þ If manually moving the equipment, push the load.
þ The prevention instructions to be carried out during the operations should be well known.
þ Use the equipment under normal working conditions (ambient temperature, atmosphere, etc.).
þ Equipment used outdoors should be protected as well as possible against bad weather conditions.
þ Notify the authorized persons after a dangerous operation or if the equipment seems problematic
(abnormal noise, abnormal behaviour, etc.)
59 10D :
Annexure Wire Rope : Basic Information, Storage & Handling
Component part
Contd….
Annexure D : Wire Rope : Basic Information, Storage & Handling 60
— Care should be taken to avoid dragging wire rope through sand, gravel and dirt since it may pick
up abrasive particles, which can cause deterioration of the rope during its use.
— wherever necessary, a wire rope, whether preformed or non-preformed, should not be cut
unless seizings are provided on either side of the cut. for multi-strand non-rotating rope at least
three seizings are suggested on either side of the cut. Ropes should never be cut with a chisel
and hammer. It should be cut either using an abrasive cutter or by gas-cutter.
Installation
— The free end of the rope must remain
tightly served / fused or welded during the
entire installation procedure. When
attaching a rope end in a wedge socket /
clamp, it is important that the entire rope
cross-section, including steel core if
applicable, be firmly secured or anchored.
— The position of the anchorage point of the drum should be located in relation to the direction of
lay of the rope. As a thumb rule, a right hand lay rope should start winding from the left hand
flange of the drum, the rope over winding and the observer standing behind the drum. The
opposite is true for a left hand lay rope, that is, the anchorage should be at he left hand flange of
the winch drum, with the observer standing behind the drum.
61 10D :
Annexure Wire Rope : Basic Information, Storage & Handling
— For the multi-layer coiling on the drum, any cross winding should be avoided by ensuring that
the rope winds uniformly in the grooves formed between the successive turns of the preceding
layer of the rope.
Maintenance :
— After installing a new rope, it is advisable to run through its normal operating cycle for a number
of trips under light load and at reduced speed. This allows the new rope to adjust itself gradually
to operating conditions and enable the strands to settle down and some stretch to occur, the
rope then becomes less liable to damage when the full load is applied.
— While hoisting or lowering, never lift or stop a load with a jerk. This shock load may equal several
times the static working load and may be suffering to break a rope. Even if the jerks do not snap
the rope, they can cause rapid deterioration resulting in reduced rope life.
The above-mentioned conditions guide general lines for discard of wire rope during use. However, the
discretion of the user or an inspecting officer, associated with the equipment or installation have be final
for judging and ascertaining the safe condition of the rope, based on his earlier observations and
experience on the particular installation. Hence, if the inspection of the rope leaves any doubt about its
safety in the mind of the user / inspecting officer, the rope should be changed.
Types of failures
Survey of removal criteria
a wire rope must be removed if one or more of the following criteria can be satisfied.
1. Broken wires
A wire rope must be discarded if the permissible number of wire breaks has reached or
exceeded. It must also be replaced when local concentrations of wire breaks occur ( discard
number of wire breaks.)
2. Reduction in diameter
Reduction in diameter can be caused by abrasion, corrosion or a local failure of the rope core.
According to B.S. 6570 a wire rope should be discarded '' when the rope diameter anywhere is
reduced to 90% of the nominal diameter in the case of six and eight strand ropes''.
Considering the fact that a rope is allowed to have an oversize of 4% when new, this figure
would allow for a diameter reduction of 14% which seems to be excessive.
For multi-strand ropes, B.S. 6570 recommends a detailed examination '' if the rope diameter
falls to 97% of the normal'', because '' discard may be necessary''.
3. Corrosion
Corrosion may be external or internal, general or localized.
According to B.S. 6570, a wire rope should be discarded '' when the surface of the wires is
severely roughened or pitted, or if the wires are slack within the strands due to wastage''.
4. Deformation of rope
waviness
This deformation, while it may not necessarily affect the strength of the rope, transmits
pulsation and produces uneven rope wire. When the rope is laid on a level surface under no load,
the maximum height of the ''wave'' should not be greater than the normal rope diameter +
1/3.Otherwise the rope should be removed from service.
63 10D :
Annexure Wire Rope : Basic Information, Storage & Handling
Loop Formations
Wire or groups of wires may form a line of loops parallel to the axis of the rope. The deformation
is often caused by shockloading. Loop formations are a justification for discard.
Loose Wires
Where loose outer wires are found without any adjacent mechanical damage, the most likely
cause will be corrosion and the rope should be removed from service. Where loose wires have
been caused by mechanical damage, a full examination will decide if the rope can remain in use.
Nodes
A node is a local increase in rope diameter with the core easily visible between several covering
strands. It can be caused by shock loading or, in the case of fibre main core ropes, by the
absorption of moisture. A node is a justification for discard.
Thinning is a reduction in the diameter of the rope over a short length. It is often associated with
older fibre cored ropes usually in areas of sustained heavy loads over sheaves. The
disintegration and loss of the core can allow one of the covering strands to take the place of the
core. When this condition occurs in ropes with IWRC the distortion will most often be in the
vicinity of the termination away from drum. The most likely cause is rope rotation which has
allowed the rope to unlay, resulting in the overload and reduction in diameter or failure of the
IWRC.
Kinks
Deformation caused by a loop in a rope being tightened when the rope cannot rotate about its
axis to release the torque. The tight bend or kink thus formed, can result in a serious loss of
strength due to unbalance in the lay lengths. Ropes with kinks must be discarded.
Flat areas
A flattening can be caused by bending the rope severely over the rim of a sheave or any sharp
object with the wires on the inside of the bend being forced out of position. Ropes with flat areas
should be discarded.
65 10E :
Annexure Safety related to load lifting accessories
Inspection points
— The wire rope sling shall not be used and shall be disposed if they are -
Points for attention
— Use only suitable wire rope slings.
— Never use damaged wire rope slings.
— During lifting, the safe working load must not be
exceeded.
— Regular inspections shall be conducted
— Sudden elevation is not allowed
— If more than one wire rope slings is used in lifting,
pay attention to the angle between the slings.
ü
The cable clip shall be properly installed according to
the following points
— The wire rope sling is equipped with thimble.
— There is a minimum of 3 cable clips.
— The direction of installation shall be correct.
— The distance between the cable clips shall be the same.
O
O
Method of connection of wire rope slings
O
ü
Annexure E : Wire Rope : Basic Information, Storage & Handling 66
Hook
Hooks are a vital part of the lifting gear. A variety of them cater to different lifting purposes.
— All hooks shall be installed with safety latched (other than specially designed hooks.)
— Hooks can be installed with swivels to allow the load to revolve.
Safety points
— The hook shall not be directly fixed to on the eye bolt.
— Plain eye bolts only apply to the vertical lifting.
— The angle of lifting of shoulder eye bolts shall not be
less than 45O.
— Washers may be used to ensure that the shoulder is
firmly in contact with the surface.
— Never use a sling through a pair of eye bolts.
Corporate Office
Branch Office
Bangalore : No 22, 3rd Floor, Above Bombay Dyeing Showroom, 5th Cross, 5th Block,
Koramangala, Bangalore 500 095 Cell : 099008 15071
E-mail : shashank@emech.in
towards Lavasa
Chennai : No. 6, 5th Floor, B Wing, Gemini Parsn Manere, No. 602 Anna Salai,
Chennai 600 006 Cell : 099406 57525
E-mail : palani@emech.in
Delhi : ElectroMech House - Flat No. 2900/3, 9th Floor, Golflink Apartments,
Nagina Co-operative Housing Society Ltd., Sector 54, Gurgaon, Haryana
Cell : 099719 43232 E-mail : yuvan@emech.in
Kolkata : 716, Jogendra Gardens, Ground Floor, Bosepukar, Kolkata 700 078
Cell : 098740 64646 E-mail : sena.biswas@emech.in
Mumbai : Technocity, B-503, Plot No. X-1/2 & X-1/4, Mahape, Navi Mumbai 400 710
Cell : 099701 73366 E-mail : runal@emech.in
www.emech.in