FOR DGOT CRANE h INDEX

Mechanism calculation for 65/20T X 22M DGEOT Crane 17-18/184/6211

Design sheet of Mechanism Calculation Date 7

Client name D Revision no 0

Prepared by Y Approved by B

SR NO. DESCRIPTION PAGE NO.

1 MH wire rope dia calculation 1

2 AH wire rope dia calculation 2

3 MH motor power calculation 3

4 AH motor power calculation 4

5 CT motor power calculation 5

6 LT motor power calculation 6

7 Cross travel wheel load calculation (MIN,MAX,MEAN) 7

8 Cross travel wheel load with impact calculation 8

9 Cross travel wheel Hardness calculation 9

10 Cross travel wheel dia selection calculation 10

11 Long travel wheel load calculation (MIN,MAX,MEAN) 11

12 Long travel wheel load with impact calculation 12

13 Long travel wheel Hardness calculation 13

14 Long travel wheel diameter selection calculation 14

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 FOR MAIN HOISTING
MOTION h WIRE ROPE CALCULATION

Mechanism calculation for 65/20T X 22M DGEOT Crane 17-18/184/6211

Design sheet of Mechanism Calculation Date 16-10-17

Client name D Page no : 1 Rev. no 0
Prepared by Y Approved by B

WIRE ROPE CALCULATATION

Fo = S x F.O.S

WHERE

Fo = - Minimum breaking load of wire rope.

S = - Max. Rope tension considering inclination of the rope in uppermost Position.
F.O.S = - Factor of safety.

CALCULATION

SWL (A) (kg)

65000
Lower block including wire rope etc weight (B) (kg)
2275
Total load (A+B) (kg) 67275
No. of falls 12
Rope tension= (total load/no. of falls) (kg) 5606.25
Max. rope tension considering inclinationof the rope in
5627.7
uppermost position. S=(Rope tension/cos 5) (kg)

F.O.S = 8

Fo = S x F.O.S (Kg) 45021 = 441.65 KN

Wire rope dia. with construction 6x36 (mm) 26
Tensile grade of steel wire (N/Sq.mm) 1960
Breaking load (kg) 48115.68 = 472.00 KN

SO THE ABOVE SELECTION IS JUSTIFIED

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 FOR AUX HOISTING
MOTION h WIRE ROPE CALCULATION

Mechanism calculation for 65/20T X 22M DGEOT Crane 17-18/184/6211

Design sheet of Mechanism Calculation Date 16-10-17

Client name D Page no : 2 Rev. no 0
Prepared by Y Approved by B

WIRE ROPE CALCULATATION

Fo = S x F.O.S

WHERE

Fo = - Minimum breaking load of wire rope.

S = - Max. Rope tension considering inclination of the rope in uppermost Position.
F.O.S = - Factor of safety.

CALCULATION

SWL (A) (kg)

20000
Lower block including wire rope etc weight (B) (kg)
600
Total load (A+B) (kg) 20600
No. of falls 8
Rope tension= (total load/no. of falls) (kg) 2575
Max. rope tension considering inclinationof the rope in
2584.8
uppermost position. S=(Rope tension/cos 5) (kg)

F.O.S = 5.6

Fo = S x F.O.S (Kg) 14475 = 142.00 KN

Wire rope dia. with construction 6x36 (mm) 16
Tensile grade of steel wire (N/Sq.mm) 1960
Breaking load (kg) 18247.26 = 179.00 KN

SO THE ABOVE SELECTION IS JUSTIFIED

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 FOR MAIN HOISTING
MOTION h MOTOR CALCULATION

Mechanism calculation for 65/20T X 22M DGEOT Crane 17-18/184/6211

Design sheet of Mechanism Calculation Date 16-10-17

Client name D Page No : 3 Rev No : 0

Prepared by Y Approved by B

MOTOR kW CALCULATIONS FOR MAIN HOIST MOTION(AS PER IS:4137)

Motor MxVxK 1
Power = X
(kW) 6.12 x E x Mf Camb.

Where

Mass of rated load + weight of hook block + weight of

M = 67.28 Tonns -
Rope .
V = 7.00 m / min. - Specified hoisting speed in m / min.

K = 1.2 - Service factor for vertical motion of M8 duty

Camb. = 0.95 - Derating factor for ambient temparature in °C of 50
Mf 1 - No off Motor Qty

E = 0.90 (Combined efficiency of Gears & Sheaves, i.e 0.99^5

i.e (0.99^5 x 0.98^3) for no. of pulley's (5) & 0.98^3 for (3) stage reduction
GB)

CALCULATION FOR HOISTING MOTION

Req.Power 67.28 X 7.00 X 1.20 1.00

= X
(kW) 6.12X 0.90 x 1 0.95

= 103.2 X 1.05

Mech power /
86 KW
Motor =
Selected Power (Frame-kw) = 110
Electrical.Power = 109 KW
TYPE: Slip Ring

SELECTED MOTOR: 355S, 110kw 989 rpm, 60% CDF,150 St/hr, 6 POLE.
NOTE: FRAME POWER AND SLIP RPM MAY VERY ACCORDING TO MANUFACTURER
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 FOR AUX HOISTING
MOTION h MOTOR CALCULATION

Mechanism calculation for 65/20T X 22M DGEOT Crane 1

Design sheet of Mechanism Calculation Date 16-10-17

Client name D Page No : 4 Rev No : 0

Prepared by Y Approved by B

MOTOR kW CALCULATIONS FOR AUX HOIST MOTION(AS PER IS:3177)

Motor M x V x Cv x Cdf 1
Power = X
(kW) 6.12 x E x Mf Camb.

Where

Mass of rated load + weight of hook block + weight of

M = 20.60 Tonns -
Rope .
V = 10.00 m / min. - Specified hoisting speed in m / min.

Cv = 0.67 - Service factor for vertical motion, for A.C motor

Cdf = 1.6 - Duty factor depend on classification of utilization M7

Camb. = 0.95 - Derating factor for ambient temparature of 50 0C
Mf 1 - No off Motor Qty

E = 0.91 - (Combined efficiency of Gears & Sheaves, i.e 0.99^3

i.e (0.99^3 x 0.98^3) for no. of pulley's (3) & 0.98^3 for (3) stage reduction.
GB)

CALCULATION FOR HOISTING MOTION

Req.Power 20.60 X 10.00 X 0.67 x 1.6

=
(kW) 6.12X 0.91 x 1 x 0.95

= 36.86 X 1.13

Mech power = 36.9 KW

Selected Power (Frame-kw) = 45

Electrical.Power = 41.59 KW
TYPE: Slip Ring

SELECTED MOTOR: 280S, 45 kw 984 rpm, 60% CDF, 150 St/hr, 6 POLE.
NOTE: FRAME POWER AND SLIP RPM MAY VERY ACCORDING TO MANUFACTURER
FOR CROSS TRAVEL
MOTION h MOTOR CALCULATION

Mechanism calculation for 65/20T X 22M DGEOT Crane 1

Design sheet of Mechanism Calculation Date 16-10-17

Client name D Page No : 5 Rev No : 0

Prepared by Y Approved by B

MOTOR kW CALCULATIONS FOR CROSS TRAVEL MOTION(AS PER IS:3177)

Motor MxV 1100 x a S 1

Power (kW)
= X( F+ )x X
6117 x T 981 x N Camb Mf

Where

Mass of rated load + weight of trolley in Tonnes = mass

M = 89.50 ` -
moved in tonnes.
V = 30.00 m / min. - Specified free running speed in m / min
T = 1.70 - Motor torque factor
N = 0.94 - Mech. efficiency of gear considering reduction of stage 3
F = 8.00 kgf / T - Frictional factor 8 kgf / T for anti frictional bearing
a = 11.00 cm / sec² - Average acceleration in cm / sec² (Considered) for Low/Mod
S = 1.4 - Service factor aimed at providing adequate motor for M7
Camb = 0.95 - Derating factor for ambient temparature of 60 ⁰c
Mf = 1 - No off Motor Qty

CALCULATION FOR CROSS TRAVEL

Req.Power 89.50 X 30.00 1100 X 11.0 1.4 1

(kW)
= X ( 8.00 + )X X
6117X 1.70 981 X 0.94 0.95 1

= 0.26 X 21.11 X 1.47 X 1

Mech. KW/
= 5.45
Power motor
Elec KW/ Selected Power (Frame-kw) = 11
= 8.03
Power motor TYPE: Slip Ring

SELECTED MOTOR: 180L, 11kw 972 rpm, 60% CDF,150 ST/HR, 6 POLE

NOTE: FRAME POWER AND SLIP RPM MAY VERY ACCORDING TO MANUFACTURER

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 FOR LONG TRAVEL
MOTION h MOTOR CALCULATION

Mechanism calculation for 65/20T X 22M DGEOT Crane 1

Design sheet of Mechanism Calculation Date 16-10-17

Client name Page No : 6 Rev No : 0

Prepared by Y Approved by B

MOTOR kW CALCULATIONS FOR LONG TRAVEL MOTION(AS PER IS:3177)

Motor MxV 1100 x a S 1

Power = X ( F+ )x X
(kW) 6117 x T 981 x N Camb Mf

Where
M = 136.00 ` - Mass of rated load + weight of crane in Tonnes
V = 60.00 m / min. - Specified free running speed in m / min
T = 1.70 - Motor torque factor
N = 0.94 - Mech. efficiency of gear considering stage reduction 3
F = 8.00 kgf / T - Frictional factor 8 kgf / T for anti frictional bearing
a = 15.00 cm / sec² - Average acceleration in cm / sec² (Considered) for Low/Mod
S = 1.4 - Service factor aimed at providing adequate motor for M7
Camb = 0.95 - Derating factor for ambient temparature of 50 ℃
Mf = 2 - No off Motor Qty

CALCULATION FOR LONG TRAVEL

Req.Power 136.00 X 60.00 1100 x 15 1.4 1

(kW)
=
6117 X 1.70
X( 8.00 +
981 X 0.94
)X 0.95
X
2

= 0.78 X 25.87 x 1.47 x 0.5

Mech.
= 10.15 KW/Motor
Power
Elec Selected Power (Frame-kw) = 15
= 14.96 KW/Motor
power TYPE: Slip Ring

SELECTED MOTOR: 200L, 15 kw 975 rpm, 60% CDF,150 ST/HR, 6 POLE

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 WHEEL LOAD
CT WHEEL LOAD h CALCULATION

Mechanism calculation for 65/20T X 22M DGEOT Crane

serial no :

Design sheet of Mechanism Calculation Date 7

Client name D Page No : 7 Rev No : 0

Prepared by Y Approved by B

CT WHEEL LOAD CALCULATION F (AS PER IS:3177):

LOAD(MAX.) = (CRANE WEIGHT + CRAB WEIGHT) LOAD (MIN.) = (CRAB WEIGHT)

NO. OF WHEELS NO. OF WHEELS

Where

CRAB WEIGHT = 24.5 T - Mass of the Crab in tonnes.

SWL = 65 T - Mass of the Rated Load in tonnes.

NO. OF WHEELS = 4 - No. of CT wheels

% OF LOAD DISTRIBUTION ON WHEEL= 0.60 ~ 60.0%

MAX. CT WHEEL LOAD CALCULATION

39.00 + 24.50
MAX. LOAD =
2 4

MAX. LOAD = 25.63 T

MIN. CT WHEEL LOAD CALCULATION

MIN. LOAD = 24.50

4

MIN. LOAD = 6.13 T

Mean load = 2xPmax+Pmin

3

MEAN LOAD = 19.125 T

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 WHEEL LOAD
CT WHEEL LOAD WITH IMPACT h CALCULATION WITH
IMPACT

Mechanism calculation for 65/20T X 22M DGEOT Crane 1

serial no :

Design sheet of Mechanism Calculation Date 7

Client name D Page No : 8 Rev No : 0

Prepared by Y Approved by B

CT WHEEL LOAD CALCULATION WITH IMPACT (AS PER IS:3177):

(SWL x Impact factor) + CRAB WT.)

LOAD =

No. of wheels

Where

CRAB WEIGHT = 24.5 T - Mass of the Crab in tonnes.

SWL = 65 T - Mass of the Rated Load in tonnes.

NO. OF WHEELS = 4 - No. of CT wheels

% OF LOAD DISTRIBUTION ON WHEEL= 0.60 ~ 60%
Impact factor for M7 = 1.4

CT WHEEL LOAD CALCULATION

54.6 + 24.5
Wheel load with Impact =
2 4

Wheel load with Impact = 33.4 T

CT Wheel load = 33.4 T

with Impact

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 WHEEL HARDNESS
FOR CROSS TRAVEL h CALCULATION

Mechanism calculation for 65/20T X 22M DGEOT Crane 1

serial no :
DESIGN SHEET OF Mechanism Calculation Date: 16-10-17

CLIENT:- D Page No : 9 Rev No : 0

PREPARED BY Y Approved by B

HARDNESS OF WHEEL FOR CT (IS: 3177)

1.3 x BHr x CL
BHw =
Cz x Cd

WHERE

BHw = - Brinnel hardness of wheel rim

® BHr = 210.00 For Ct Rail = CR-80 - Brinnel hardness of rail
Factor dependent on rail length 'L' used by 'Z' no. of
CL = 1.11 Span of crane = 22 wheels. For values refer table 6. (Clause 8.6.3, IS
- 3177:1999)

Factor dependent on the no. of load carrying wheels 'Z'.

Cz = 1.08 No off wheel = 4
For values refer table 7. (Clause 8.6.3, IS 3177:1999)
-

Factor dependent on the wheel diameter 'D'. For values

Cd = 1.12 wheel Diameter = 400 -
refer table 8. (Clause 8.6.3, IS 3177:1999)

CALCULATION FOR WHEEL HARDNESS

1.30 x 210 x 1.11

BHw =
1.08 x 1.12

® BHw = 250.52

SELECTED VALUE OF Cbh AGAINST BHw

® of 280
= 6.7 Refer clause 8.6.6, IS 3177:1999) Pg. No.-15

Wheel hardness is maintaned at 300BHN however for calculation 280BHN is considered

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 FOR CROSS TRAVEL h WHEEL DIAMETER CALCULATION

Mechanism calculation for 65/20T X 22M DGEOT Crane 1

no :

Design sheet of Mechanism Calculation Date 7

Client name D Page No : 10 Rev No : 0

Prepared by Y Approved by B

DIAMETER OF WHEEL FOR CT AS PER IS:3177

(P)mean x Cdf x Csf

D =
1.5 a x Cbh x Csp

WHERE
D = - Min. Thread diameter of wheel in mm
Cdf = 1.4 - Duty factor for horizontal motion for class M7
Csf = 1 - Safety factor depend on material used
Cbh = 6.7 - Hardness factor for the wheel material
Csp = 1.03 - Co-efficient depend on the speed of rotation of wheel
Pm = 191250.00 19.13X10000 Newton - Mean wheel load in Newton
a = 76.0 mm - Useful top width exclude radii for Rail of CR-80

Convex bearing surface = B - 4r/3 - B = Width of rail = 87 mm

- r = Radious = 8 mm
= 76.33 mm

CALCULATION FOR DIAMETER

191250.00 x 1.40 x 1
D =
1.5 x 76.0 x 6.70 x 1.03

® D = 340.34 mm

SELECTED DIAMETER OF WHEEL(D) = 400.0 mm X 4Nos

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 LT WHEEL LOAD h WHEEL LOAD CALCULATION

Mechanism calculation for 65/20T X 22M DGEOT Crane 1

no :

Design sheet of Mechanism Calculation Date 16-10-17

Client name D Page No : 11 Rev No : 0

Prepared by Y Approved by B

LT WHEEL LOAD CALCULATION F (AS PER IS:3177):

(Span - Hook
(CRANE WEIGHT - CRAB WEIGHT) + (SWL+ CRAB WEIGHT)
LOAD (MAX.) = X Approach)
NO. OF WHEELS NO. OF WHEELS 2 / Span

(Span - Hook
(CRANE WEIGHT - CRAB WEIGHT) (CRAB WEIGHT)
LOAD (MIN.) = + X Approach)
NO. OF WHEELS NO. OF WHEELS 2 / Span

Where

CRANE WEIGHT = 71 T - Mass of the Crane in tonnes.

CRAB WEIGHT = 24.5 T - Mass of the Crab in tonnes.

SWL = 65 T - Mass of the Rated Load in tonnes.

NO. OF WHEELS = 8 - No. of LT wheels

Span = 22 m
Hook Approach = 2.7 m

MAX. LT WHEEL LOAD CALCULATION

71.00 - 24.50 65 + 24.5 22.00 - 2.700

MAX. LOAD = + x
8 4 22.00

MAX. LOAD = 5.81 + 22.375 X 0.88

MAX. LOAD = 25.44 T

MIN. LT WHEEL LOAD CALCULATION

When SWL = 0
71.00 - 24.50 0 + 24.5 22.00 - 2.700
MIN. LOAD = + x
8 4 22.00

MIN. LOAD = 5.81 + 6.125 X 0.88

MIN. LOAD = 11.2 T

Mean load = 2xPmax+Pmin

3

MEAN LOAD = 20.69 T

0
 LT WHEEL LOAD WITH WHEEL LOAD
IMPACT h CALCULATION WITH IMPACT

Mechanism calculation for 65/20T X 22M DGEOT Crane 1

serial no :
Design sheet of Mechanism Calculation Date 16-10-17

Client name D Page No : 12 Rev No : 0

Prepared by Y Approved by B

LT WHEEL LOAD CALCULATION WITH IMPACT (AS PER IS:3177):

(CRANE WEIGHT - CRAB (SWL x Impact factor) + (Span - Hook

LOAD = WEIGHT) + CRAB WT.) X Approach)
NO. OF WHEELS NO. OF WHEELS 2 / Span

Where

CRANE WEIGHT = 71 T - Mass of the Crane in tonnes.

CRAB WEIGHT = 24.5 T - Mass of the Crab in tonnes.
SWL = 65 T - Mass of the Rated Load in tonnes.
NO. OF WHEELS = 8 - No. of LT wheels
Span = 22.00 m
Hook Approach = 2.7 m
Impact factor for = 1.4 for class of duty = M7

LT WHEEL LOAD CALCULATION

Wheel load with 71.00 - 24.50 91 + 24.5 22.00 - 2.70

Impact
= + x
8 4 22.00

Wheel load with

= 5.81 + 28.875 X 0.88
Impact

LT Wheel load = 31.1 T

with Impact

0
 WHEEL HARDNESS
FOR LONG TRAVEL h CALCULATION

Mechanism calculation for 65/20T X 22M DGEOT Crane 1

serial no :
DESIGN SHEET OF Mechanism Calculation Date: 16-10-17

CLIENT:- D Page No : 13 Rev No : 0

PREPARED BY Y Approved by B

HARDNESS OF WHEEL FOR LT (IS:3177)

1.3 x BHr x CL
BHw =
Cz x Cd

WHERE

BHw = - Brinnel hardness of wheel rim

® BHr = 210.00 For Lt Rail = CR-100 - Brinnel hardness of rail
Factor dependent on rail length 'L' used by 'Z' no. of
CL = 1.29 Bay length of crane = 210 wheels. For values refer table 6. (Clause 8.6.3, IS
- 3177:1999)

Factor dependent on the no. of load carrying wheels 'Z'.

Cz = 1.08 No off wheel = 4
For values refer table 7. (Clause 8.6.3, IS 3177:1999)
-

Factor dependent on the wheel diameter 'D'. For values

Cd = 1.12 wheel Diameter = 400 -
refer table 8. (Clause 8.6.3, IS 3177:1999)

CALCULATION FOR WHEEL HARDNESS

1.30 x 210 x 1.29

BHw =
1.08 x 1.12

® BHw = 291.15

SELECTED VALUE OF Cbh AGAINST BHw

® of 315
= 8.7 Refer clause 8.6.6, IS 3177:1999) Pg. No.-15

Wheel hardness is maintaned at 300BHN however for calculation 280BHN is considered

0
 FOR LONG TRAVEL h WHEEL DIAMETER CALCULATION

Mechanism calculation for 65/20T X 22M DGEOT Crane 1

no :

Design sheet of Mechanism Calculation Date: 16-10-17

Client name D Page No : 14 Rev No : 0

Prepared by Y Approved by B

DIAMETER OF WHEEL FOR CT AS PER IS:3177

(P)mean x Cdf x Csf

D =
1.5 a x Cbh x Csp

WHERE
D = - Min. Thread diameter of wheel in mm
Cdf = 1.4 - Duty factor for horizontal motion for class M7
Csf = 1 - Safety factor depend on material used
Cbh = 6.7 - Hardness factor for the wheel material
Csp = 0.91 - Co-efficient depend on the speed of rotation of wheel
Pm = 206895.83 20.69X10000 Newton - Mean wheel load in Newton
a = 97.0 mm - Useful top width exclude radii for Rail of CR-100

Convex bearing surface = B - 4r/3 - B = Width of rail = 108 mm

- r = Radious = 8 mm
= 97.33 mm

CALCULATION FOR DIAMETER

206895.83 x 1.40 x 1
D =
1.5 x 97.0 x 6.70 x 0.91

® D = 326.51 mm

SELECTED DIAMETER OF WHEEL(D) = 400.0 mm x 8No.'s