TECHNICAL SPECIFICATION OF OVERHEAD CRANE  15 TONS

1. STANDARD Equipment is designed and constructed to fulfil the requirements of an internationally recognised standard as mentioned below. The standards to which the quoted items are compliant are specified. The standard approval certificate of the crane is provided with the offer.

Design Code

EU design code EN 15011-1 in conjunction with FEM / DIN (Equivalent or Higher)

Classification

M5–M6 (based on duty cycle)

Safety Factors

Structure  ≥ 1.5

Wire ropes ≥ 5

Brakes

Brakes should be fail-safe and have a safety factor of

at least 2.0 to ensure they can stop the crane even in the event of a system failure

2. AMBIENT CONDITIONS The ambient conditions at which the machine will be used are as follows:

Air Temperature   050C - 450C

Water Temperature: :050C - 400C

Relative Humidity:  Upto 98% Non-Condensing

Water Quality:  Muddy and sandy (Colocation of Meghna river)

Salinity: Up to 34 gm/ltr

Wind Speed: 40-50 m/sec (highest) [Average 4.5m round the year]

Seismic Zone: Zone-II ((seismic intensity: moderate)

3. SCOPE OF SUPPLY The scope of supply is to include the following: 

Complete set of Overhead Crane with accessories, including rails, fittings, mountings, and other necessary items for immediate operation

Documentation

Local training

Certification

Installation to be made by OEM as per the instructions of the manufacturer or

OEM Representative

4. TOOLS Standard tools for the maintenance work  supplied with the machine as per OEM  Recommendation

5. TECHNICAL SPECIFICATIONS

Model

 Model: OC15_6x18_55

   Type: EOT, double girder (Preferred, to be mentioned)

      Rail line: 55.0 m (approx., as required), grade DIN536 A75 or higher (to be mentioned).

    Span (c/c distance) 18.0 m (approx.) Shall be installed as per the drawing.

    Lifting height: (main hoist): From Ground to at least 6m below hook (To be mentioned)

    Main hoist capacity: 10 tons. (SWL)

    Hoist type: KULI Hebezeuge

      Main hook

 Minimum capacity:15 tons with a load indicator.

      Heavy-duty forged steel hook: 360° swivel Thrust bearing-mounted, safety latch-equipped

    Main hoist lift speed: 10m/min (min) and to be mentioned

    Cross speed: 10 – 20 m/min (adjustable), to be mentioned

    Long speed:  20 - 40 m/min (Adjustable), to be mentioned

   Speed variation range: To be mentioned

   Crane Weight: 18 tons

    Control system: Remote Controlled (Remote operated at a distance of greater than 15m radius).

          Radio remote control (Industrial grade)

     Variable Frequency Drives (VFD) for smooth operation

    Overweight Sensor: Include

     Limit switch: Include

   Control System: Include an independent panel for the hoist.

     Operating conditions: Indoor (with in boat workshop)

     Rigidity, Control & Safety  The crane is rigid, robust, and of sturdy construction, following:

       Crane controls are conveniently located. Various controls are suitably interlocked to prevent accidental movement of the crane.

       Suitable limit switches, one each for long and cross travel, and two for main hoists, are provided to stop the crane and prevent over-travel of various moving parts of the crane. Suitable   buffers are provided to prevent overtravel of the crane

mechanism in both longitudinal and cross-traverse directions

     Suitable guards or enclosures are provided on the crane to prevent

inadvertent contact with down shop leads (DSL) or any other exposed electrical conductors and cables

     Suitable isolation switches and stop buttons are provided to isolate the electric supply for maintenance or in the event of an emergency

     A safety hand railing of tubular construction shall be provided on bridge footwalls, end carriages, trolley and any other places where access is provided.

     All sheaves are provided with rigid guards to retain the ropes in the grooves.

     The crane shall comply with the relevant safety regulations

      Maintainability

      Safe access for maintenance and removal of all mechanical, electrical, and

structural components ensured.

      All electrical cables are so laid that they are not liable to damage and

easily inspected and maintained

Materials used for equipment and structural shall be free from cracks, blow

holes, laminations, pitting etc. 

A toolbox containing all tools required for the maintenance of the crane is supplied with the crane

Fasteners for pedestal blocks, gear boxes, etc., are easily removable from the top of the platform

      Structural Details

      The crane bridge comprises double girders of plate box type. Camber

In the box girder, as per the relevant international code

All welded subassemblies of the box girder are stress relieved before final welding of the box girder

Position of the weld joints in the top plate, side plate and bottom plate of the box girder assembly is specified with respect to the maximum deflection plane (i.e. plane passing through the center point of the box girder).

      All fasteners hot dip galvanized

     The bridge girders are connected to the end carriages by large gusset plates.

      All butt welds on structural members of bridge girders subjected to tension

radiographically tested

The box girders are so constructed as to eliminate any possibility of accumulation of water or oil inside them

 End Carriages

     Crane bridge carried on end trolleys with solid forged wheels

End carriages are designed to be strong enough to resist all stresses likely to be imposed upon them under varied service conditions, including collision with stops. The length of the end carriages is such that no other part of the crane is damaged in the event of a collision

End carriages are fabricated from rolled steel sections or plates, welded together to form a box. Suitable stiffening diaphragms are provided

wherever required.

Suitable jacking pads are provided on each end carriage for jacking up the crane while changing track wheels. These jacking pads shall not interfere

With the replacement of track wheels

The end carriages are fitted with suitable safety stops to prevent the crane from falling more than 25mm in the event of breakage of track wheel, bogie or axle. These safety stops do not interfere with the removal of track wheels

 Crane rails

     Crane rails for longitudinal and cross travel supplied, installed and tested by the supplier. The relevant dimension of the crane rail DIN 536 A75, material 900A or equivalent

 Trolley frame

     The trolley frame is a welded rolled steel box section, designed to

transmit the load to the bridge rails without undue deflection. It shall be made rigid by providing suitable diaphragms

The drum bearings and supports for upper sheaves are located so as to equalise the load on the trolley wheels as nearly as possible

The trolley wheels are suitable for the crane rails

All the mechanical and electrical equipment is placed above the trolley top plate as far as practicable

 Rail wheels

     The rail wheels are suitable for the crane rails mentioned

The wheels shall be manufactured from medium carbon alloy steels, and solid forged and heat-treated

The wheels   shrink-fit on the axles

      No of wheels commensurate with crane, rail and maximum dynamic loading

  Rope drums

     The rope drum is designed to withstand the compressive stresses

caused by the rope wound on it and the bending stress due to the beam action of the drum

The steel used conforms to ASTM S275 or higher (International equivalent quality).

      The drum is designed to take the entire length of the rope in a single layer.

Cranes designed with a number of ropes having 4 falls

Weld joint of the web with rope drum shaft, and the inner diameter of the rope drum radio graphed. This applicable for seamless rope drum.

Wire Rope

    Wire rope in the crane of galvanised type and of reputed make. It 6 x 36 construction or equivalent and made from the best plough steel of tensile strength 180 kg/ mm2

 Gearing

     Only suitable gears are used. Gearing in all motions shall be of suitable case carburising low carbon alloy steels and conform to the relevant

international standards

 Gear boxes

     All gearboxes of the completely enclosed splash-lubricated type. All gearboxes shall be oil-tight and sealed with neoprene ‘O’ rings of suitable

section

All gearboxes have drip pans to avoid oil falling on the shop floor

Motors

Three-phase squirrel cage crane duty TEFC induction motor

For Long Travel

The wheels of each end carriage are driven by

independent synchronised drive motors mounted near each end carriage for long travel (LT).

For Cross Travel

A separate cross-traverse motor is used for

cross traverse (CT) drive through a suitable gearbox

For Hoist

A separate hoist motor is used for the hoist drive

through a suitable gearbox.

Brakes

     For L T & C T motions

The maximum braking torque to arrest long travel and cross traverse motions shall not be less than 100% of full load torque for each brake. The L T & C T brake   provided with fail safe DC

disc type 01 no for each

For hoist motion, two brakes used and the braking torque for each brakes hall not be less than 125% of full load torque. One of the two hoist brakes  applied with a time lag of 3 seconds in relation to the first

Electro    Hydraulic

Thruster Brake

01 in no

Fail-safe D.C.  Disc

brakes

01 in no

   Brake release is dependent on motor torque. The brake is released only if 100% torque is developed in the motor

 Rope sheaves

    All sheaves of cast/ forged steel. They shall be identical, with the exception of the equaliser sheave. The equaliser sheave  is mounted above the trolley floor and is easily accessible and   removable from the trolley floor level. Sheave grooves smooth finished for getting increased rope life. The supplier further ensures

that the wire ropes are parallel with each other

Bearings

     Ball and roller anti-friction bearings  of reputed make

For long and cross-traverse wheels, spherical roller bearings are used. Bush bearings are not be used at any location

Lifting hook

Standard plain shank type trapezoidal section hooks with load indicator shall be used. These hooks shall conform to the relevant International Standards and full load requirement

Buffers

Spring-loaded or other suitable buffers are fitted on the four corners of the crane, also at the four ends of the bridge girders. Buffers are rigidly bolted in place, preferably along the center line of the crane rail or trolley rail, as the case may be. All buffers have sufficient energy-absorbing capacity to stop the bridge or trolley in either direction when travelling at a speed of least 40% full load rated speed. Bridge buffers shall have a contact

surface of not less than 125 mm in diameter.

Lubrication

All gears and bearings enclosed inside gearboxes are splash-lubricated.

Bottom blocks and pedestal bearings have independent greasing points

A lubricating chart provided in the manual indicates all lubrication points, the type of lubricants required and the recommended frequency of lubrication. These details are repeated and amplified, if necessary, in the Maintenance Manual to be supplied along with the crane

Scope of supply for electrical components

All accessories and auxiliary electrical equipment, including drive motors, electrically operated brakes, controllers, AC variable frequency controls, conductors, protective devices, operating devices, cables, conduits, etc., necessary for the safe and satisfactory operation and maintenance of the crane included in the Vendor’s scope of supply. Electrical equipment adequately rated to permit the simultaneous operation of any combination of motions of the crane for its duty service. The scope of  supply relating to the electrical portion covers:

Indicating lamp and sound alarms: All indicating lamps shall be LED type with appropriate protection. The sound alarm shall have a sufficient dB level so that it is audible in the crane operating area

Shrouded down shop leads with LED lamps for three-phase power indication

Main current Collectors (one in the forward and another in the rear).

Power disconnecting switch on the crane bridge walkway, to be provided immediately after the main current collection gears

Protective Switch Gears

Motor control panels

   Socket outlets.

      IGUS Drag link cable system

      Earth wire on the crane portion as per the relevant International Standards.

      Shrouded bus bar GI conductor along with Isolator switch at the ground level. Cabling from the Isolator to the shrouded bus bar should be in the vendor’s scope.

Three 250 W Metal Halide luminaries under the crane, operable from

pendant as well as from the wireless remote control 

All sundry erection material required for the installation and connecting up of electrical equipment, with cable laying and fixing accessories, is included in the price of the crane

Power  supply conditions

The available power supply in Bangladesh is 400- 440 V, 50 Hz, 3-phase. The machine should have a tolerance of ± 10% voltage fluctuation

  Crane control

      The crane control system is a versatile joystick, radio-controlled 

supplied for reliably controlling crane hoists.

   A radio control key, an Actuated/ Joystick Transmitter be supplied for easy operation

      High-level safety trough greater distance from the load

      Should be highly reliable Data transmission

      Rugged housing/ casing

      Proper agronomic design

      Fast and versatile operation

      Bi-Directional signal Transmission

      Simple and first commissioning by wire, transmitter log on

Graphic display showing battery capacity & installation states with warning massages

Convenient operation for smooth & precise travel

Highly available by high-speed transmitter charging (within 2 hours).

Emergency operation is possible with conventional Mig-non AA type batteries

(key actuator transmitter).

Impact and Temperature resistance housing design

Integrated impact protection

No registration & operation fees (to log in).

1 joystick for lifting/lowering axes.

1 joystick for two axes (cross & long travel).

1 horn/start button

1 limit switch test button

2 push buttons for special function

Mechanical key-operated switch to turn the transmitter on & off

Weight including rechargeable battery (to be mentioned).

IP 55 enclosure

Temp. range 50 to 450 c

  AC  variable frequency control drives

Independent AC variable frequency control drives of adequate capacity for main hoist, CT & LT are used by using independent variable voltage variable frequency drives suitable for crane application. However common controller for both

the motors of LT are to be used.

  Contactors

All contactors of AC 4 Class of duty with a rating sufficiently higher than the full load current of the respective motors at the specified duty cycle. The directional contactors of all motions are suitably interlocked for the correct sequence of operation.

 Circuit protective switch gear

     In the crane; push button operated contactor shall be provided for the circuit protection

Each control circuit branch to every contactor panel  provided with

facility for isolation and protection against short circuits and sustained high overloads by means of an appropriately rated miniature circuit breaker

   MPCB (Motor protection circuit breaker) is used for each drive motor.

  Limit switches & locks.

Hoist motion shall be provided with limit switches to prevent the crane from overhoisting and overlowering. Two limit switches are provided for proper backup protection. One of the limit switches is based on Gravity. The first limit switch acts in the event of over-hoisting and over-lowering of the snap action/ pin type self-resetting feature, and is incorporated in the control circuit of the respective drive motor.

Other limit switches for slewing, skewing of the crane, etc.  provided

      Long travel and cross travel motions are provided with two limit switches at each end.

  First limit switch

- To change the travel speed to creep speed.

   Second limit switch

- To stop the supply to the relevant motor for further motion. This action shall be accompanied by an alarm sound and light indicating that the maximum limit reached

Limit switch for hoist cross and long travel motion is supplied and installedand wired by the manufacturer

Audio & Visual Alarm for all the limit switches  provided

Safety latch and swivelling lock  provided for the hook

  Emergency  stop push buttons

Safety switches of sustained contact type are provided at each end of Crane Bridge so that under any emergency conditions, by operating anyone of the switches, the incoming circuit breaker is tripped thus cutting power to all motions. One emergency stop push button will also be provided on the pendant.

 Control panel (IP 55 class protection).

All power and aux contactors are mounted in a sheet steel cubicle with lockable hinged doors. Door hinges of such a type that during the repair works inside the panel, the entire door can be lifted out and placed away, enabling better access inside the panel. Each motion has its own panel. However, a common panel with a separate compartment for each motion is acceptable. Interiors of panel   dust and vermin-proof

    Panels front wired with readily accessible terminal blocks for making connections in the external equipment. Panels are pre-wired into the terminal strip. Single-core, copper conductor   used   for the  control circuit wiring in the panel

  All contactors, etc., are mounted securely in a vertical arrangement with consideration of the vibrations encountered in the operation of cranes. The bottom-most row of the equipment mounted inside the panel, except terminals strips   at least 150 mm above the panel's bottom cover to facilitate inspection and repairs

   All the equipment is mounted in a panel so as to enable its easy removal/ replacement from the front

The terminal strips fixed inside the panel preferably in a horizontal manner leaving enough space underneath the strip for termination of cables in a convenient manner. Power and control terminals are segregated. Power terminal blocks shall be separated from each other by means of replaceable insulated spacers. The terminal block has adequate clearance to avoid tracking. A minimum of 20% spare terminals block shall be provided in terminals strips.

     All equipment’s inside the panel have permanent identification labels in accordance with the circuit diagram as well as the power and control terminals.

Terminal blocks shall be of robust and of such construction as to preclude the possibility of cable connections getting loose during vibration on the crane.

    Sheet steel used for the fabrication of panels shall have a minimum thickness of 2.0 mm. Panels mounted such that the bottom of the panel is at least 150 mm above the floor.

   Contactor panels shall be well-braced to the crane structure, and each panel shall be provided with an adequate number of lifting lugs.

    All the panels and cabinets are provided with CFL luminaires for interior illumination.

 Cabling.

    All wiring for the power control circuit was carried out with 1.1 KV grade Flame Retardant Low Smoke (FRLS) PVC-insulated copper cables as per

    International Standards in conformity with the full load range

  All cables are systematically laid on G.I. trays or in cable drags of suitable type.

  All cables of reputed make and approved international brands.

  Earthing

Earthing to the crane affected through the track rails crane structure. Equipment fed by flexible cables, earthed by means of a spare core provided in the flexible cable.

 Safety

The crane is a fail-safe machine (The crane and the accompanying load should be safe even in the event of a system failure). It has standard safety features, including: Standard safety features 

 Safety device

In an emergency, due to any brake malfunctions, to avoid the free fall of loads Guided lowering system be incorporated to avoid the free fall of loads, thus ensuring high safety. To be checked and certified by the OEM during the erection & commissioning of the crane.

Painting and Corrosion protection

Shot blasted to SA 2.5 before painting

Primer

Epoxy Zinc Phosphate Primer (min 40 μm DFT)

Technical Parameters

Top Coat

Polyurethane/Enamel Paint (min 100 μm DFT)

Total

Min 140 μm DFT

Pins and Joints

Stainless steel or hot-dip galvanising MS

Standard

     The machine is to be designed and constructed fulfilling the requirements of the international standard as mentioned above. The standard to which the quoted machine complies is to be

specified in detail.

Standard and Necessary Accessories

Main item with manufacturer recommended all standard (ISO & ICS Standard) and necessary accessories and attachments (price included in the total price) for smooth and immediate operation of the Machine without the requirement of any other items (attachments, accessories, consumables, etc.) to be supplied with the machine. A list of standard and necessary accessories be submitted with the offer.

Standard and Special Tools

Standard and special tools and equipment required for the erection and commissioning of the machine shall be brought by the supplier. Manufacturer recommended standard and necessary tools (price included in the total price) for operation and maintenance of the machine should be supplied. A list of standard and special tools will be submitted with the offer.

Optional Items

    A list of optional items (if any) indicating item-wise price (price not included in the total price) which may be required for the advanced operation (OEM Recommended) of the Machine is to be       provided. A list with technical details of these items, including the following, should be given with the offer.

Spare Parts

     A list of recommended fast moving spare parts with item wise price (price not included in the total price) for the machine is to be provided with the quotation.

Documents

     Two (02) sets of the following documents (in English language) are to be provided free of cost along with the machine:

a. Operation and maintenance manual 

b. Workshop level repair manual (including various repair instruction, clearance, tolerance, material specifications, etc).

c. Installation instructions and drawings

    d. Parts catalogue with internationally recognised part no.

    e. Electrical and Electronic circuit diagram and wiring diagram.

Supporting Documents Including  Product Brochure/ Catalogue

    01 (one) set of original brochure/ booklet, operation and maintenance manual, products catalogue in English, including detailed technical information about the quoted calibrator with accessories are to be provided along with the quotation for evaluation/ assessment. Non-submission of such supporting documents will render the offer technically non-responsive.

Local Training

    The supplier/ manufacturer is to arrange operation, maintenance and fault-finding training by the supplier/OEM representative in the premises under the training schedule.

Warranty

a. Minimum 12 (Twelve) Month’s warranty for trouble-free operation is to be provided by the supplier/ manufacturer for the item from the date of acceptance by the buyer. If any component of the supplied items becomes defective during the warranty period, the warranty shall be extended automatically (for the relevant component) for the period during which the subject component remains defective.

b. For warranty repair/ replacement, the supplier will collect the defective item, re-supply the same to the collecting place after warranty repair or for replacement within 90 (ninety) days from the date of defect at no cost to the purchaser.

Guarantee

The supplier is to give guarantee to supply the spare parts for at least 05 years at a reasonable price.

 Quality   Assurance Certificate

Quality Assurance Certificate in respect of the associated  equipment with regard to  its

manufacturing and performance is to be provided at the time of delivery of the items.

Certificate

    The supplier will provide the following certificates:

    a. Manufacturer’s Authorisation Certificate with the offer

    b. Pre-delivery Inspection Certificate (in English) prior to delivery is to be provided by the supplier.

    c. Load Certificate (Crane Wire and Hoist)

    d.  Safety Certificate

    e. Supply Assurant Certificate.