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FOREWORD
This standard was first published in 1967and revised in1985. The necessity for
the revision has arisen in view of the experience gained by the industry during the course
of the implementation of the standard. In this revision the material of components has
been upgraded, stress relieving of material included, mechanical design parameters and
electrical equipments requirements, manufacturing and erectioning have been modified
in line with revised version of IS 807:2006 Design, Erection and testing (Structural
Portion) of Cranes and Hoists - Code of Practice and IS 3177:1999 Code of practice for
of overload traveling cranes and gantry cranes other than steel work cranes
( Second Revision)The components are designed and selected on more rational basis.
This code covers design, manufacture and erection of heavy duty electric over
head traveling cranes for use in steel works. Steel plant cranes and special service
machines covered in this standard are listed in Appendix A. Also covers mechanical,
electrical, inspection and testing aspects as related to design, manufacture and erection of
electric overhead traveling cranes for use in steel works in order to secure safe, efficient
and reliable working of these heavy duty cranes during service. Structural design aspects
of all types of cranes and hoists are covered in IS807:2006 Design, Erection and testing
(Structural Portion) of Cranes and Hoists - Code of Practice, Mechanical, electrical,
inspection and testing aspects of overhead traveling cranes -and gantry cranes other than
steel work cranes are covered separately in IS : 3177:1999. Cranes are broadly classified
into four classes in IS: 807-1976” depending on duty and number of hours in service per
year. In IS : 3177-1977 the different motions of a crane and the design of component
parts are required to be treated on the basis of mechanism classification defined in terms
of the severity of duties to be performed or average life of mechanism or the component
part.
All the necessary information regarding the conditions under which the crane is to
be used together with the particulars laid down in Annex A shall be supplied with the
enquiry or order. The manufacturer shall supply with the tender the information in
accordance with the proforma laid down in Annex B.
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IS 3177:1999 Code of practice for of overload traveling cranes and gantry cranes other
than steel work cranes ( Second Revision)
IS 807 : 2006 Design, Erection and testing (Structural Portion) of Cranes and Hoists -
Code of Practice
The committee kept in view the manufacturing and trade practices prevailing in the
country while formulating the standard. Assistance has also been derived from the
following publications:
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CONTENTS
Section I - GENERAL
Page
1.1. SCOPE……………………………………………………………………………………………………………..…….09
1.1.1 TERMINOLOG……………………………………………………………………………………………....…..09
2.1.6 STRESSES……………………………………………………………………………………………….…..………14
2.1.12 ROPES………………………………………………………………………………………………………….…………20
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2.1.16 BUMPERS………………………………………………………………………………………………………… 26
2.1.19 BEARINGS………………………………………………………………………………………………………….30
2.1.23 LUBRICATION………………………………………………………………………………………………....36
2.1.25 RAILS……………………………………………………………………………………………………………………..38
2.1.28 GUARDING…………………………………………………………………………………………………………..40
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3.1.1 GENERAL…………………………………………………………………………………………………………...45
3.1.2.1 GENERAL……………………………………………………………………………………………………....46
3.1.2.2 CONDUCTORS……………………………………………………………………………………………..46
3.1.3.1 GENERAL………………………………………………………………………………………………………..47
3.1.3.2 CONDUCTORS…………………………………………………………………………………………....47
3.1.4 EARTHING………………………………………………………………………………………………………....47
3.1.4.1 GENERAL…………………………………………………………………………………………………………47
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DEVICES………………………………………………………………………………………………..…..…50
3.2.1.1 GENERAL…………………………………………………………………………………………………….....59
3.2.1.2.1 GENERAL……………………………………………………………………………………………………..62
3.2.1.4 CONTACTORS………………………………………………………………………………………………..66
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3.3.1 GENERAL…………………………………………………………………………………………………………….....80
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3.5.1.2.1 GENERAL…………………………………………………………………………………………………….112
3.6.1 LIGHTING…………………………………………………………………………………………………………....118
3.6.1.1 CABIN………………………………………………………………………………………………………………...118
3.6.4.1 GENERAL…………………………………………………………………………………………………….....120
3.6.4.2 MAGNET…………………………………………………………………………………………………………...121
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4.1.34 TESTING……………………………………………………………………………………………………....133
APPENDIX
C Selection of motors…………………………………………………………………………………...147
D Rating of Resistors…………………………………………………………………………………....150
E Preferred parameters……………………………………………………………………………....150
F Reference Standards……………………………………………………………………………....151
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SECTION I - GENERAL
1 SCOPE
1.1 This code covers design, manufacture and erection of heavy duty electric over
head traveling cranes for use in steel works. Its provisions where applicable, shall also
apply to special service machines, such as those listed in Annex A.
1.2 This crane service classification system applies specifically to fatigue strength
analysis of Mechanical components. The maximum rated load will also be used to check
the crane for static strength, buckling, deflection and stability.
1.3 The concept of classification may also enter into the rating and selection of electrical
equipment and provide guidance for the selection of components which have a metal life
between replacement.
1.4 This code is not intended for application to cranes for use in areas where sparks from
cranes could lead to explosions. Which are covered IS 3177.
2 REFERENCES
The standards given in Annex A contain provisions, which through reference in this text,
constitute provisions of this standard. At the time of publication, the editions indicated
were valid. All standards are subject to revision and parties to agreements based on this
standard are encouraged to investigate the possibility of applying the most recent editions
of the standards indicated at Annex G.
3 TERMINOLOGY
For the purpose of this standard the definitions given IS 13472 (Part 1)1992/ ISO 4306-1:
2007 shall apply.
4 IDENTIFICATION
4.1 A small plaque shall be located in a prominent position in the cab bearing the
following inscription:
a) Manufacturer’s name;
b) Manufacturer’s serial number; and
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c) Year of manufacture
d) Capacity of each hoist shall be shown on each side of crane in such a
manner as to be easily legible from the floor.
Information regarding the conditions under which the crane is to be used, together with
the information required in Annex B, shall be supplied with the enquiry or order.
The manufacturer shall supply all tender documents including drawings giving the over
all sizes, clearance, end approaches, structural features, travel wheel loads, end carriage
buffers, impact forces, wheel spacing, etc.,
Workmanship and material shall be subject to the inspection of the owner or his
representative at all times. Weldments of carbon steel (except bridge girders) shall be
stress relieved by uniformly heating in a furnace. Field welds shall likewise be stress
relieved unless other means agreeable to the owner as specified in the information sheet.
The temperature of the furnace when the weldment is placed in it shall not be over 150°C
at the start and increased to 650°C at a rate not exceeding 95°C/hour, and then held at the
temperature for 1 h/25mm of thickness of material. It shall then be cooled in the furnace
at a rate (not exceeding 95°C/hour) to 260°C, before being removed from the furnace.
Weldments of alloy material shall be welded and stress relieved using a procedure
specified by the owner.
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5. CALCULATION PROCEDURE
5.1 Mechanism components shall be designed by checking that they offer required
safety against failure due to fracture, crippling, fatigue or excessive wear. Other
factors shall also be taken into consideration and it is particularly important to
avoid over heating or deflection which may interfere with correct functioning of
the mechanism.
5.2 CHECKING FOR ULTIMATE STRENGTH
Mechanism components shall be checked for ultimate strength by verifying that the
calculated stress shall not exceed a permissible stress dependent on the braking
strength of the material used.
5.3 VALUE OF THE PERMISSIBLE STRESS
The value of the permissible stress σa is given by the following formula:
σa = σR/VR , Where:
σa is the ultimate stress of the material
VR is a safety coefficient corresponding to each case of loading.
5.4 VALUE OF THE COEFFICIENT VR
The values to be adopted for VR are given in table I below:
Table I
Case of lading IV exceptional loading condition
Value of VR 1.8
5.5 Relations between the calculated stresses and the permissible stresses.
According to the types of loading considered, the following relations shall be
verified in which:
σt is the calculated tensile stress
σC is the calculated compressive stress
σf is the calculated bending stress
σs is the calculated Shear stress
(a) Pure tension : 1.25 σt ≤ σa
(b) Pure compression : σc ≤ σa
(c) Pure bending : σf ≤ σa
(d) Combined bending and tension: 1.25 σt + σf ≤ σa
(e) Combined bending and compression: σc + σf ≤ σa
(f) Pure Shear : √3 σs ≤ σa
(g) Combined tension, bending and shear:
[(1.25 σt + σf )2 + 3 σs 2] o.5 ≤ σa
(h) Combined compression, bending and shear:
[( σc + σf )2 + 3 σs 2] o.5 ≤ σa
5.6 CHECKING FOR FATIGUE
General method -The fatigue strength of a given component is mainly determined
by the following factors
a) The material from which the component is constructed.
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b) The shape, surface condition, state of corrosion, size (scale effect) and
other factors producing stress concentration.
c) The ratio between the minimum and maximum stresses which occur
during the various stress cycles.
d) The stress spectrum
e) The number of stress cycle
5.7 STRESSES
The following characteristics shall be determined for each type of fluctuating stress,
tension, compression, bending or shear, occurring during an appropriate stress cycle
in the component details having regard to the loading that it will experience.
ƒmax, ƒmin = extreme values of stress occurring in the stress cycle.
ƒmin = considered as negative if it is of opposite sense to ƒmax
Pfb = permissible fatigue stress in bending
Pts = permissible fatigue stress in shear
Pfb = fatigue reference stress at which a component details has a 90 percent
probability of survival
ƒomax, ƒamin = extreme values of axial tensile stress.
ƒbmax, ƒbmin = extreme values of stress in bending
ƒsmax, ƒsmin = extreme values of torsional shear stress
ƒmax, ƒmin = Max degree of stress fluctuation.
5.8 PERMISSIBLE FATIGUE STRESS
The permissible fatigue stress ‘Pfs’ for each type of stress, tension, bending or shear
is given by:
Pfs = 0.8 Pfr for hoisting mechanisms
= 0.85 Pfr for all other mechanisms.
Where the component detail is subjected to a single type of fluctuating stress, that is
ƒmax shall not exceed Pf the permissible fatigue stress.
The stress combination occurring most frequently in practce in a component detail
is that of bending and torsion. The details subjected to this combination shall be
designed so that
( ƒb Max )2 + ( ƒs Max )2 < 1.0
Pfb Pfs
5.9 CHECKING FOR CRIPPLING
Component subjected to crippling that in overall flexural buckling due to axial
compression shall be checked so that the calculated stress does not exceed a limit
stress determined as a function of critical stress above which there is a risk of
crippling occurring. For this check co-efficient Cdf of IS 3177 (Table 2).
5.10 CHECKING FOR WEAR
In the case of parts subjected to wear, the specific physical quantities such as
surface pressure or the circumferential velocity shall be determined.
NOTE: Annex B of IS 3177shall be referred for calculating the fatigue stress Pfr.
5.11 HOOKS
5.11.1 Generally hooks shall be designed material clause as per IS 3664 for infinite life
based on the rated load except where the owner specifies finite life design. The design
shall be established by analysis or testing.
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5.11.2 Hooks shall be forged from fine grain material. Any welding on the hook shall be
with the approval of a qualified welding engineer and performed prior to initial heat
treatment. The capacity of the hook may be stamped on the hook nose. The hook shall
not be painted.
5.11.3 Hook shank
The calculated maximum stress at the root of the thread of the shank section,
including a fatigue stress concentration factor for the type of thread used, shall not
exceed 0.33 of minimum ultimate tensile strength at mid-radium.
5.11.4 Considerations:
Due consideration shall be given to impact, service and to the possibility of bending
forces on the hook shank. These bending forces will be partially dependent upon the
geometry of the hook saddle and the coefficient of friction between the hook saddle
and the loading element.
The shank shall be undercut below the last threads for a length of at least two pitches
to allow for a uniform stress flow. The undercut shall have a radius at each change in
diameter.
5.11.5 Hook Body
Hook bodies shall be as per IS 3664 where the line of the resultant load on the hook
passes through the center of curvature of the inside edge of the hook and coincides
with the centreline of the shank. The lifting Hooks shall comply with IS 3815 and IS
5749. The maximum combined stress at the inner surface of curvature of the critical
section 90 degrees from the vertical load shall not exceed 0.33 time of minimum
ultimate strength. This applies to hook bodies of trapezoidal section. Where square
or rectangular sections are used, these stresses shall be reduced by at least 10 %.
5.11.6 Testing
Where hook capacity has been established by testing, the static load required to
straighten out the hook body shall not be less than 5.0 times the rated load.
A certificate of compliance showing both fatigue and static load testing covering both
the configuration of the hook body and the hook shank shall be provided.
Approval by the owner shall be obtained for hooks selected on this basis.
5.11.7 Sections
Proportions of hook sections other than the critical section shall be such that the stress
does not exceed the stress in the critical sections.
5.11.8 Threads
The hook nut and shank threads shall provide required strength for the hook capacity.
Due consideration shall be given to the weakening effect of the nut locking
arrangement.
5.11.9 Latches
Hook latches and swivel lock plates shall be provided when specified.
5.11.10 Laminated Point hooks
Laminated hooks shall be made for steel works and foundries for lifting and carrying
molten masses in spigot ladles. The material, dimensions, design, components and
assembly for laminated point hooks are covered IS 5749 and part and technical
delivery conditions for laminated hooks are covered IS 5749.
5.12 ROPE DRUMS
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5.12.1 Drum shall be rolled or centrifugally cast steel as per IS 2328 Flanged ends, if
required, shall not be less than 2.5 mm in thickness and project not less than 65
mm. beyond the pitch diameter of the drum.
5.12.2 Drums shall have wrapped grooves of a depth equal to 12 mm of the diameter of
the hoisting rope and a pitch of not less than 1.2 times this diameter. The groove
radius shall be 0.8 mm in. larger than the radius of the rope. Drums shall be
designed so that not less than two complete wraps of hoisting rope will remain in
the grooves ahead of the first rope clamp when the hook is at the lowest position.
In addition, it shall be possible to lay the hook block on the floor for maintenance
with one full wrap remaining on the drum.
5.12.3 One empty groove for each rope shall be left on the hoist drum when the hook is
in the highest position. This provision is to insure that overlapping of the rope
will not occur when the hook is in the highest drifted position.The pitch diameter
of the drum for 6 x 36 wire rope shall not be less than 30 times the diameter of the
hoisting rope used for Classes M7 and M8 cranes.
5.12.4 Radius of the bottom of the groove
The useful life of the rope depends not only on the dia of the pulleys and drums, but
also on the pressure exerted between the rope and the groove supporting the rope.
The winding ratios are given as the radius of supporting groover where r = 0.53 d, d
being the nominal dia of the rope.The drum gear shall be keyed and pressed on to
the periphery of the hub or shell of the drum, or shall be bolted with fitted bolts to a
flange on the drum or by other attachment means as approved by the owner. The
lead angle of the rope shall not exceed 5o on either side of helix angle of the groove
in the drum. The contour at the bottom of the grooves shall be circular over a
minimum angle of 120o.
5.13 ROPES
5.13.1 The hoisting ropes shall be of the grade and type specified in IS 2266. Based on
the static breaking strength, a design factor of 8 shall be used for hot metal handling
hoists and 5 for hoists other than hot metal handling.The sheave arrangement should
be reeved so as to eliminate reverse bends except at the drum.
5.13.2 The maximum allowable fleet angle for frequent working positions shall be 2½
degrees for Classes M7 and M8 cranes. The maximum allowable fleet angle for
seldom reached positions shall be 3½ degrees for Classes M7 and M8 cranes.When
special reeving, such as a stabilised reeving arrangement is used, consideration must
be given to geometry and dynamics to maintain the appropriate safety factors.
Provisions should be made to prevent the twisting of the hook block.
5.13.3 Where load swinging can occur due to the crane service, rope lead angles shall be
set, or other provisions made, to minimize or eliminate the possibility of the rope
skipping grooves on the hoist drums. When designing hoist drums the following
should be taken into consideration. On high duty cycle cranes, drum grooves
should be flame hardened to a minimum of 400 BHN.
5.13.4 The minimum breaking load Fo of the intended for a particular duty shall be
determined from the formula given below, however impact factor shall not be
considered while calculating the rope tension
Fo = S x Zp x Cdf
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W x Cdf x Csf
D=
1.5 a x Cbh x Csp
Where:
D – Tread dia of the wheel in mm
W – Maximum wheel load in newtons
a – useful width of rail
Cdf – duty factor undefined in 7.4.3 of IS 3177
Cbh – hardness factor for the wheel. For values refer Table 9 of IS
3177
Bhw – as calculated in 7.4.3 of IS 3177
Csf – safety factor depending on the material used as defined in
7.4.3 of IS 3177
Csp – Co-efficient depending on the speed of rotation of the wheel
defined in Table 10 of IS 3177.
5.16.4 Determining the mean load
In order to determine the mean loads, the procedure is to consider the maximum
and minimum loads with stood by the wheel in the loading cases considered, i.e.
with the crane in normal duty but omitting the dynamic factor. The values of P
mean shall be determined by the formula for loading case I and II, III
P mean = (P min I, II, III + 2 P max I, II, III) / 3
5.16.5 Determining the wheel width
a) Flat bearing surface : a = B – 2r
b) Convex bearing surface : a = B – 4r/3
where:
B – width of the rail, and
R – radius of the rounded corners of the side
5.16.6 Flanges
The dimensions of flanges for guiding trade wheels at the base shall not be less
than the values given in Table 11 of IS 3177/1999.
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5.17 BUMPERS
5.17.1 Provisions in the design of the runway and the design of the runway stops shall
consider the energy absorbing or storage device used in the crane bumper. The
device may be nonlinear (e.g hydraulic bumpers) or a linear device such as a coil
spring.
5.17.2 The maximum deceleration rate for both bridge and trolley shall not exceed 5 m/s2
at l50% of the full load rated speed (full load rated speed shall be used unless
adequate information is supplied by owner to determine the actual attainable
maximum speed.) Additionally, bumpers shall be capable of absorbing the total
energy at 100% full load rated speed.
5.17.3 Between cranes or trolleys (if two trolleys are located on one bridge) bumpers
shall be capable of absorbing the energy from 70% of full load rated speed of both
cranes or trolleys travelling in opposite directions, or the energy from 100% of
full load rated speed of either crane or trolley, whichever is the greatest.
5.17.4 The design of all bumpers shall include safety cables to prevent parts from
dropping to the floor. For computing bridge bumper energy, the trolley shall be
placed in the end approach which will produce the maximum end reaction from
both bridge and trolley. This end reaction shall be used as the maximum weight
portion of the crane that can act on each bridge bumper. The energy absorbing
capacity of the bumper shall be based on power-off and shall not include the lifted
load if free to swing. Bridge bumpers shall have a contact surface of not less than
125 mm in diameter, be located on the rail centreline and mounted to provide
proper clearance when bumpers of two cranes come together and both are fully
compressed. Where practical, they shall be mounted to provide for easy removal
of bridge track wheels.
5.17.5 Buffers shall have sufficient energy absorbing capacity to bring the loaded cranes
or crab to rest from a speed 50 percent of the rated speed at a deceleration rate not
exceeding 5 m/s2.
5.18 SHAFTING
5.18.1 Hoist shafting design torque shall be based on the torque required to lift the rated
load plus hook block and/or lifting beam and shall take account of mechanical
efficiencies. Design torque for all travel drives shall be based on 2 times the 60
minute motor rating for series wound, constant potential D.C drives, and 1.7 times
the 60-minute motor rating for A.C motors and adjustable voltage D.C drives
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without motor field weakening, or wheel slip at maximum wheel load (0.20
friction factor) whichever is lower. Due consideration shall be given to the
maximum brake torque which can be applied to the drive.
Axles or shafts which are provided with sleeve bearings are to be surface or case-
hardened and ground.
5.18.2 Shafts
All shafts shall be made of low alloy steel of C 45 and axles shall have strength,
rigidity and required the bearing surfaces. All shafts shall be supported on
minimum two bearing. Angular deflection of the line shaft at torque
corresponding to 1.5 times the motor torque during the acceleration period shall
not be more than 0.25o per meter of shaft length. The drive for line shaft shall be
mounted as close as practicable to the centre of the span.
5.18.3 Stress calculations - All shafting shall be designed to meet the stresses encounted
in actual operation. Due consideration shall be given to the maximum Torque which
may be applied to the shaft. When significant stresses are produced by the other
forces, these forces shall be postioned to provide the maximum stresses at the section
under consideration. Impact shall not be included.
5.18.4 Fatigue stress check for normal operating conditions - Any shafting subjected to
fluctuating stresses such as the bending or rotating shafts or the torsion in
reversing drives must be checked for fatigue. The bearing stress must not exceed
50% of the minimum yield strength for non - rotating shafting.
5.19 PRESS FITS AND KEYS
5.19.1 Keys shall be provided for all connections subject to torsion. All gears, pinions
and couplings shall be pressed or shrunk onto shafts in addition to being keyed.
All press fits shall be made in accordance with IS: 2048/1983 Preferred Limits
and Fits for Cylindrical Parts. All keys and keyways shall be radiused and/or
chamfered according relevant Indian Standard.
5.20 BEARINGS
5.20.1 Antifriction bearings shall be spherical, tapered, straight. Antifriction bearings
shall be selected on the basis of B-10 life, to give a minimum life expectancy of
ten years or 5,000 to 40,000 hours under the service conditions for which the crane is
intended. Bearing selection in this specification is based on the total number of
cycles which it is expected the bearing will undergo during the number of hours
service the crane will be used in a 10 year period.
5.20.2 All bearings selected shall meet the required life at 75% of the maximum bearing
load (at rated speed) based on the recent catalogue rating of the bearing
manufacturer. Bearings are selected for 75% of the maximum load (at rated
speed) on the assumption that this gives a practical average value for fatigue life
purposes. If the load on the bearing is essentially constant, the bearings must
meet a required life of 100% of the maximum load at rated speed. In some cases
axle sizes establish bearing sizes.With wheel bearings of the antifriction type, one
bearing on each wheel axle shall be of the fixed type. The other bearing shall be
arranged to allow for expansion or float of the axle.
5.20.3 Lubrications-Provisions shall be made for the service Lubrication of all the
bearings unless sealed and lubricated for life. Ball and roller bearings shall be
lubricated before assembly.Gear housings shall be split or designed to permit easy
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removal of the shaft.Gear reduction units should be designed so that gears, shafts
and bearings, as well as bearing cartridges and end pieces, can be pre-assembled
as a spare.Drum bearings and supports for the upper sheave block shall be located
so as to equalize the load on track wheels as near as possible.
5.20.4 Bearing Brackets and Housing
Bearing brackets, if not integral with the frame, shall be mounted on a machined
surface and be kept in alignment by fitted bolts or other equally effective
methods. When shafting is geared together the support structure for all bearing
cartridges should, where practical, be integral and located as close as possible to
the gears and pinions. Heavy caps shall be provided with a means for lifting.
5.21 GEARING:
5.21.1 Gearing types
Gearing shall be spur, herringbone, helical as specified in the IS 4460, 7504. No
split gears or overhung gears shall be used without specific approval of the owner.
5.21.2 Gearing Design:
Horsepower ratings for all spur and helical involute gearing shall be based upon
American Gear Manufacturers Association or IS 4460 Fundamental Rating
Factors and Calculation Methods for Involute Spur and Helical Gear Teeth.
5.21.3 Allowable Stress (Sac) and (Sat)
The allowable stress for contact stress (Sac) and for bending stress (Sat) and
material used shall be as listed for Grade I material as per IS 4460.
5.21.4 Dynamic Factors (Cu) and (Ku)
The dynamic factors for pitting resistance (Cu) and for bending strength (Ku)
shall be as per Paragraph 8.3.2 and 8.3.3 of AGMA 2001 B-88 based on the
lowest quality member in the mesh.
5.21.5 Elastic coefficient, (CP)
The elastic coefficient (CP) shall be as per IS 4460.
5.21.6 Hardness Ratio Factor (CH)
The hardness ratio factor (CH) shall be as per IS 4460.
5.21.7 Service Factors
The service factors (CSF) and (KSF) shall be used as per IS 4460.
5.21.8 Maximum and Minimum Gearing Face width:
The gearing face width shall be a maximum of 1.4 times the pinion pitch diameter
and a minimum of 3 times the circular pitch.
5.21.9 Gear Design Loading
Hoist gear loading for bending strength and pitting resistance shall be based on
the torque required to lift the rated load plus hook block and/or lifting
beam.Travel drive gear ratings for bending strength and pitting resistance shall be
based on 2 times the 60 minute motor rating for series wound constant potential
D.C drives, and 1.7 times the 60 minute motor rating for A.C motors and
adjustable voltage D.C drives without motor field weakening, or wheel slip at
maximum wheel load (0.20 friction factor) whichever is lower. Due
consideration shall be given to the maximum brake torque which can be applied to
the drive.
5.21.10Dynamic Response
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Where unusual drive arrangements are employed the dynamic response of the
system should be analysed to ensure that any additional loadings are identified.
5.21.11Drum Gear Alignment-The effects of trolley frame and rope drum deflections on
the alignment of the hoist drum gear and pinion shall be considered.
5.22 MACHINING REQUIREMENTS
5.22.1 Machining and Inspection-All gears shall be 20º pressure angle full depth tooth
form and shall have a full root radius unless this compromises other design
considerations. The wall thickness over the keyway of pinions shall be atleast
equal to the tooth depth and the rim thickness of gears shall be atleast 1.2 times
the tooth depth. Gears shall not have a shoulder or step left in the fillet area.
5.22.2 Bores - Bores for gears requiring heat treatment shall be finish-machined or
ground to size after heat treatment and shall be no harder than 345 BHN for Class
G-1; 300 BHN for Class G-2; and 269 BHN for Classes G-3 and G-4.
5.22.3 Keyway Tolerances - Keyway tolerances to be in accordance with relevant Indian
Standards.
5.22.4 Effective Case Depth - The effective case depth for carburised and hardened gears
is defined as the depth below the surface at which the Rockwell “C” hardness has
dropped to HRC 50.
5.23 GEAR BOXES –
5.23.1 All gears shall be completely enclosed in gear boxes which shall be attached to
rigid supports. All gear boxes except for drum ring gears shall be oil-tight and sealed
with compound or gaskets.The bottom of the gear boxes shall be split horizontally
above the oil level. Easily accessible drain plugs and breathers shall be provided.
Oil level dipsticks shall go directly into the main body of gear box.
5.23.2 Openings shall be provided in the top section for the inspection of gearing at mesh
lines. Gear box inspection cover plates should provide reliable sealing, and be
easily opened and resealed.
5.23.3 In Classes M7 and M8, bearings shall be mounted in cartridges. Cartridges shall
be held in place by tapped bolts and flanges. Splash oil lubrication of bearings
may be used unless otherwise specified. Oil pumps shall be used if vertical
gearing exceeds two reductions. On horizontal gearing, the oil level shall be
above the smallest gear.
Oil seals shall be sized to allow replacement with split seals. Through bolts should
be used to hold the gear cases together and to mount the gear box to its base.All
gear cases shall be mounted on machined surfaces. Shims shall not be used.
5.23.4 Gear box seats shall be of sufficient size to allow the installation of shear blocks to
locate the gear box positively.
Gear boxes shall be provided with lifting lugs that are suitable for use in lifting
the whole gear case assembly without tilting.
5.23.5 The gear box mounting shall be machine cut, hardened and profile ground to
relevant Indian Standards and shall be seated and positively located on machined
surface. The fabricated gear boxes shall be stress relieved before machining. The
internal surfaces of the gear box shall be painted with oil resisting point. All
gearing not enclosed in Gear boxes which may constitute a hazard under normal
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The clamps shall be spaced at not more than 900 mm centres. Heat treated rail
shall be used for increased rail life. The rails shall be welded together by flash
butt welding or thermit welding.
5.27 OPERATOR’S CABIN
5.27.1 Type and location - The operator’s cabin may be of the fixed/moving type as
required by the purchaser.
5.27.2 Structure - The cabin shall be rigidly built of structural steel and fire proof
material and shall be braced to prevent movement between cabin and supporting
members. It shall be supported by rivets or bolts in shear. The head room of the
cabin shall not be less than 2 M.
5.27.3 In ladle cranes, other cranes handling hot materials and outdoor cranes, cabins
shall be totally enclosed, unless otherwise specified.
5.27.4 The cabin of outdoor shall be weatherproof.
5.27.5 Cabin Access - The entrance to the cabin shall be fitted with a door located for
safe access. The cabin floor shall be extended outside the cabin on the side
containing the door, and if necessary, sideways also to form a platform unless
otherwise required. Suitable hand railing should be provided on the platform.
5.27.6 Accessibility to the bridge platform shall be through the stairs.
5.27.7 Visibility and Field of vision - Cabins shall be so designed that under all operating
conditions the field of vision of the driver is adequate.
5.27.8 Lighting, heating, ventilation and air-conditioning: Fixed service lighting shall be
installed to provide glare free illumination in the crane cabin.
5.27.9 All cabins shall be provided with an air circulating fan of minimum sweep 400
mm.
5.27.10 All air-conditioned cabins shall be fitted with a suitable hydraulic door
closer and temp in the cabin shall be around 25ºC.
5.27.11 A suitable Co2 type fire extinguisher shall also be provided.
5.27.12 The cabin shall have a robust seat with a fixed or hinged base and a durable
upholstered squab. The seat shall be capable of withstanding severe braking
force.
5.28 MEANS OF ACCESS
5.28.1 General requirements - Safe means of access shall be provided to the driver’s
cabin and adequate hand-holds and foot-holds shall be provided, where necessary.
5.28.2 Platform - Every platform shall be securely fenced with double tiered guard rails
having a minimum height of 1.1 metre.
5.28.3 Ladders - Sides of ladders shall extend to a reasonable distance above the
platforms. Vertical ladders exceeding 3 metre in length shall be provided with
back safety guards.
5.29 GUARDING -
5.29.1 All gear wheels, pinions and chain drives shall be totally enclosed. Effective
guards shall be provided for revolving shafts and couplings. Long travel cross-
shafts and couplings above the top platform shall be guarded wherever necessary.
The sheaves of hook blocks shall be guarded to prevent the trapping of a hand
between a sheave and the in-running rope and shall be enclosed except for rope
opening.
5.30 WEATHER PROTECTION
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5.30.1 For outdoor cranes all electrical and mechanical equipment shall be adequately
protected from weather. All weather proof covers shall be easily removable.
5.31 PAINTING -
5.31.1 Before the despatch of cranes, the complete crane covering structural, mechanical
and electrical parts shall be thoroughly cleaned of all dirt, grease, scales, rust and
given a single coat of primer. All components shall be given two finishing coat of
paint of colour as per customer’s choice.
5.32 HANDLING FACILITIES:
5.32.1 Suitable structures at all four corners for handling the track wheels, should be
provided. However for all outdoor goliath and semi-goliath cranes, this facility
shall be provided.
5.32.2 All cranes shall be provided with jack pad on both end carriages and trolley
structures in such a way so as to facilitate removal of wheels, wheel bogie and
compensating bogie.
5.33 BRIDGE AND TROLLEY DRIVES-
5.33.1 Bridge and trolley drives arrangements may cover most types of crane drives
regardless of the number of wheels.
5..33.2 Bridge drives- Bridge drive shall consists of one of the following arrangements,
and these arrangements cover most four or eight wheel crane drives.
5.33.3 DRIVE I-The motor is located near the centre of the bridge and connected to a
self-contained gear reduction unit located near the centre of the bridge. Output of
the Gear reduction shall be connected directly to the truck wheel axle by means of
suitable shafts and couplings.
5.33.4 DRIVE II The motor is connected to a self contained gear reduction unit located
near the centre of the bridge. The Truck wheels shall be driven through gears
pressed and keyed on their axles or by gears fastened to, or integral with, the
Truck wheels and with pinions mounted on the end section of the cross-shaft. The
end sections of the cross-shaft shall be connected by suitable couplings.
5.33.5 DRIVE III-The motor is located at the centre of the bridge and is connected to the
cross-shaft and gear reduction units with suitable coupling. Self-contained gear
reduction units located near each and of the bridge shall be either directly
connected to the wheel axle extension or connected to wheel axles by means of
shafts in the suitable couplings.
5.33.6 DRIVE IV-The motors are located near each end of the bridge without torque
shafts. The motors shall be connected to self-contained gear reduction units. The
gear reduction unit shall be applied to the truck wheels by means of both suitable
shafts and couplings or directly mounted to the wheel axle shaft extension.
Another variation of this drive would separate the high speed and final reductions
by locating the motors near each end of the bridge without torque shafts.
5.33.7 DRIVE V-The motor is located near the centre of the bridge and in connected to a
self-contained gear reduction unit located near centre of the bridge This reduction
unit shall be connected by sections of cross-shaft having suitable couplings to
self-contained gear reduction units located near each end of the crane, and these in
turn connected to truck wheel axle by means of shafts with suitable coupling.
5.33.8 DRIVE VI-The motors are located near each end of the bridge and connected with
a torque shaft. On the drive end, the motors shall be connected to self-contained
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gear reduction units by suitable couplings. The output of the gear reduction units
shall be connected directly to the truck wheel axle by means of suitable shafts and
couplings.
5.34 TORSIONAL DEFLECTION AND VIBRATION
Natural frequency and amplitude of total torsional deflection of the drive system
should be determined. Low frequencies and large total torsional deflections are
undesirable for crane operation.
5.35 MOTION LIMITING DEVICE
Positive by operated hoisting motion limiting devices shall be provided that stops
the upward and downward motion when predetermined level is reached to prevent
over winding or over unwinding.
NOTE:-The limiting device shall be regarded as a safety feature and not as a
routine operational means of stopping. Where normal operation of the crane
necessitates frequent approach to the upward limit, an additional motion limiting
device shall be provided that operates independently and require manual settings.
5.36 CROSS TRAVEL AND LONG TRAVEL LIMITING DEVICES:
The limiting devices shall prevent the following conditions:
(a) Over traversing and over travelling, and
(b) Collision where two or more crane/Trolleys operating on the same track.
5.37 LOAD INDICATION AND LOAD LIMITING DEVICES
Load indication and limiting devices are recommended it weights of objects to be
lifted are not known accurately. When fitted, they shall sense the load on the
crane by means other than the current consumed by the hoist motor. If the load
lifted is more than SWL load limiting devices shall stop further hoisting operation
till the load is removed or reduced.
5.38 DRAWINGS AND DOCUMENTS
Following drawings and documents shall be submitted for approval of the
purchase before manufacturing of the crane:
(a) GA drawings of the crane
(b) GA drawings of crab/Trolley
(c) GA drawings of individual mechanisms
(d) Drawings of bridge, end girder and their connection
(e) Sub-assembly drawing for wheels, hook blocks and hoist drums.
(f) Calculation for selection of motor, reducer brake, couplings, etc.
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6.4 EARTHING
6.4.1 General-The crane structure, motor frames, and metal cases of all electrical
equipment including metal conduit or cable guards shall be effectively connected to earth
complying with Indian Electricity Rules (See IS 3043). A flexible metallic tube or duct
may not form an effective earth connection. The crane wheels shall not be used as means
of earthing.Where the crane is connected to the supply by flexible cord or flexible cable,
the crane shall be connected to earth by means of a separate earthing conductor enclosed
with the current carrying conductors.Travelling cranes connected to the supply through
collectors shall be effectively earthed through a fourth lead or through a set of collectors
sliding on the gantry rail with reference to IS 3043.The purchaser shall arrange for the
earthing of the gantry and/or the long travel earth conductor.
6.4.2 Control Circuit Earthing
One end of the secondary winding of control circuit transformer shall be earthed. One end
of the coil of all relays and contactors shall be connected to earth side of the control
circuit supply and this connection shall not be interrupted by any fuse or contact.In the
case of dc control circuits one pole of the rectifier shall be earthed.
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c) Methods of installation
d) Grouping
e) Intermittent duty applications
6.6.2 Co-ordination between conductors and protective devices
a) In all cases, the following relationships shall exist:
Ib < = In
Ib < = Iz
Where
In = is the nominal current or current setting, in amperes, of the over current protective
device
Iz = is the effective current carrying capacity, in amperes, of a cable for continuous
Service under the particular installation conditions concerned.
b) Where the over current protective device is intended to provide overload protection,
the following relationships shall exist:
Ib < = In < = Iz
I2 < = 1.45 x Iz
where I2 is the minimum current, in amperes, that when maintained for 1 hour will cause
the protective device to open the circuit
c) Where the over current protective device is intended only to provide short circuit
protection:
In may be greater than Iz and
I2 may be greater than 1,45 Iz
However, it should be remembered that the higher In is in relation to Iz , the greater is the
possibility of exceeding the ultimate short-circuit conductor temperature in the event of a
short circuit. That is particularly true in the case of the smaller conductors ranging in size
up to 16 mm2.
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the inductive part of the supply impedance need to be taken into account. Drop due to
reactance should also be checked.The cross-section of the conductors should be
determined by taking into account the mechanical strength required and the electrical
load to be carried. Looping cable may be provided in parallel after checking the limit of
voltage drop.When calculating the voltage drop, the most unfavourable position of the
hoisting appliance in relation to the supply point must be considered.When calculating
the admissible voltage drop on a supply line used by several hoisting appliances, the start-
up (ID) and rated (IN) currents of the motors operating simultaneously must be taken into
account.
Table No: 2.1
For all lifting appliances as a whole
Number of hoisting
Motion-1 Motion-2 Motion-3 Motion-4
appliances on one
Motions in decreasing order of
main contact line (highest rating in kW)
power.(kW)
1 X X
2 X X X
3 X X X
4 X X X X
5 X X X X
Two hoisting
appliances working X X X X
together
Table No: 2.2
Number of For all the hoisting appliances as a whole
appliances on one Motion-1 Motion-2 Motion-3 Motion-4
main contact line ID IN ID IN ID IN ID IN
1 X X
2 X X X
3 X X
4 X X X
5 X X X X
2 appliances
X X X X
Working together
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drop. The cables selection, testing shall be as per IS: 694, IS 554 and IS 9968 part
1 and Part 2.
b) Protection: All cables shall be adequately protected against mechanical damage
and metal trunking may be used if desired. If electric conduit is used it shall be
welded conduit complying with the to relevant Indian Standard.
c) Where cables are drawn into a steel tubes, the steel tube shall be heavy gauge,
welded or solid-drawn, screw-jointed and drained.
d) For outdoor cranes, except where flexible unarmoured cables are essential, cables
shall be either armoured or enclosed throughout their length in galvanized
trunking or conduit either flexible or rigid. A flexible metallic tube or duct shall
not be used as an earth connection. Taped and braided varnished cambic insulated
cables shall not be used for out-door cranes.
e) Installation; The cable and wiring systems for each motion shall be independent
and common returns shall be avoided. Main cables and controlled wiring shall be
effectively separated. Where there is incidence of direct radiation of heat, the
cable shall be protected by a shield of sheet metal.
f) Cables shall be adequately secured to the main structure of the crane having due
regard for the weight of the cable and the possibility of vibration. Where mineral
insulated metal cables are subject to the effects of high transient voltage they shall
be suitably protected by the use of surge limiting devices.
g) Cables remaining alive when a main isolator is opened shall have metallic
protection and shall be separately installed.
h) Cable runs shall not be installed in any place where they will impede the crane
driver’s field of view.
i) Due consideration shall be given during the design of the crane to make suitable
provision for cable runs and to avoid cable runs in locations where high
temperatures and mechanical damage are likely to be experienced under service
conditions. The cables should be easily accessible and should not hamper the
movement of persons on the crane.
j) Suitable precaution shall be taken to prevent the ingress or collection of water or
oil in any part of a conduit or trunking system.
k) Termination: Where trunking is used it shall extend into the electrical compartment
or enclosed units. It shall be terminated as close as practicable to motors, collector
gear and master controllers. Where junction boxes are necessary, as at motors
equipped with flexible tails, these boxes shall be rigidly fixed to the crane
structure close to the end of the trunking. Flexible or rigid conduit may be used to
protect the cables between the trunking and the connected apparatus.
l) Conduit systems shall be continuous to switch boxes and conduit outlets.
m) Cable tails shall be suitably insulated and mechanically protected, and shall be
suitably supported with insulated cleats, where necessary, to ensure rigidity.
n) Identification: Cores of multicore cables shall bear a distinguishing mark or tape.
p) Cable ends and terminals shall be ferruled at both ends and permanently marked
with numbers or letters to correspond with the diagrams or connections to be
supplied.
6.7 ELECTRICAL PROTECTIVE AND SAFETY EQUIPMENT
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crane control circuits is live, shall be provided in a position visible to the driver from his
normal working position. If specified, the main isolating switch on the bridge shall be
fitted with a pair of auxiliary contacts which will be closed when the main switch is open
and vice-versa, to operate the crane warning lights
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power supply to the motion drives with under voltage protection shall be provided.
Suitable protection against short circuit shall be provided at each of the isolator positions.
The circuit breaker of the main contactor shall be rated to carry at least the combined full
load currents of motors for any two motions having largest powers and auxiliary loads
such as magnet, etc., if specified by the purchaser that more than two motions may be
operated simultaneously, circuit breaker/main contactor shall be rated to suit the
requirement. In appropriate cases, high rupturing capacity fuse may be provided. The
circuit-breaker shall incorporate thermal and electro-magnetic overload protection device
for protection against sustained overload and short circuit condition. If adequate
protection against short circuit is to be provided at each isolating positions, there will be
either HRC fuses or MCCB/ACB in each isolating position. As HRC fuses may lead
single phasing only MCCB should be provided in each isolating position. The circuit
breaker or main line contactor should not be rated to carry magnet full load current as
magnet supply is taken before the circuit breaker/main line contactor. The breaker shall
have adequate rupturing capacity to withstand and clear fault current of the system. If
specified a suitable control circuit may be provided for this circuit-breaker to prevent it
from being closed when the main contactor of a particular motion has failed to open,
although the corresponding controller has been brought to its ‘zero’ position.
6.7.2.3 Scheme A – Protective Device for Individual Motions
The provision of overload protection with adjustable inverse time log overload release
shall be under-voltage release and with overload. The minimum provision of overload
protection shall be such that all supply lines except one to each motion shall be provided
with adjustable inverse time-lag overload releases. These shall be connected as close as
possible to the contractors they control and shall be set to trip the circuit of the motion
controlled when carrying 200 percent of the full load current of the motor, after a time-
lag of not more than 10 s. It shall not be possible to reinstate the current supply to the
contactor closing coils of a motion until the master controller for that motion is returned
back to the ‘off’ position.
6.7.2.4 Ac Instantaneous Release Single Pole over Load: Protective Device for
Individual Motions:
Any motor having its power less than one-third that of the largest motor and served by
the same common overload release, shall be protected by a separate overload release.
However, normally instantaneous release of overload relays are not used for individual
motion and circuit breaker is tripped by its own overload. In crane with circuit breaker
overload protection is provided by circuit breaker. In cranes with line contactor one triple
pole magnetic overload relay rated for total crane power may be provided to trip the main
contactor. Adjustable overload releases shall be provided to trip the main contactors or
circuit-breakers and shall be connected as close to them as possible. The minimum
provision for over current protection shall be as given below:
a) one instantaneous release in a common line feeding all motions set to trip
the main contactors or circuit breakers instantaneously when the current
rises to 250 percent of the value specified above; and
b) One inverse time-lag release in each other line feeding each motion, set to
trip the respective motion when carrying 200 percent of the full load current
of the line, after a time-lag of approximately 10 s.
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It shall not be possible to reinstate the current supply to the common main contactor
closing coils, or complete the under voltage circuit of the circuit breakers until the master
controllers for all motions are returned to the ‘off’ position.
6.7.2.5 Protective Devices for Motor circuits
The number of overload devices and their position shall normally be in accordance with
the arrangements shown in Table 14. If specified by the purchaser, other arrangements
giving protection not less than any of these shall be considered as complying with the
specification.
Table 14 Normal Requirements for Number of Protective Devices for Circuit
Dc Supply 3-phase ac
No line earthed One line earthed supply
2 per motion in separate lines 1 per motion 3 per motion in
connected in the non- separate lines
earthed line.
6.8 Contactors
Reversing contactors shall be interlocked, preferably mechanically as well as electrically
so that only one directional contactor can be in the closed position.
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feed the following auxiliary circuits where they exist. Distribution boards shall
comply with relevant Indian Standards, except that semi-enclosed fuses shall not
be used.
a) fixed Cab Cranes:
- One distribution board for crane lighting circuits as follows:
- Cab service and maintenance lighting: cab and bridge approaches and electrical
equipment compartment lighting; warning lights; in ac crane, the step down transformer
supplying the socket outlets and walkway, and bridge lighting for illuminating the floor
area.
- One distribution board for cab heating circuits, fan and air conditioning circuits, if
provided.
b) Moving Cab Cranes:
- One distribution board for bridge lighting circuits, as follows:
- Warning or signal lights; in ac cranes, the step down transformer supplying the
bridge socket outlets, and walkways and bridge lighting.
- One distribution board for crab lighting circuits, as follows:
- Cab service and maintenance lighting; cab and bridge approaches and electrical
equipment lighting and in ac cranes, the step-down transformer supplying the
crab socket outlets.
- One distribution board for cab heating circuits, fan and air-conditioning circuits.
6.16 Auxiliary switches other than Isolation switches
6.16.1Each auxiliary circuit shall be provided with a totally enclosed lighting
switch component complying with relevant Indian Standard (See Appendix
C). These auxiliary switches shall be located as follows:
i. For the equipment in the cab, such as fans and air-conditioners;
ii. For the electrical compartment lighting, at the door of the compartment;
iii. For the cab approaches, bridge approaches, and bridge walkway lighting such
that an operator can illuminate the approaches or walkways without traversing
them
iv. For the bridge lights on the crane bridge, at the crane entrance platform in fixed-
cab cranes and on the bridge in moving cab cranes; and
v. Non-fusible double pole emergency switches should be connected in series for
opening the circuit breaker or main contactors on the protective panel.
6.16.2These switches when ‘OFF’ will open both the main lines of the
protective panel control circuit and will be located at the following places
one in driver’s cab within the easy reach of the driver and one on each of
the landing corners of the end carriages to be easily accessible to a person
when boarding the crane or getting down from it. Additional switches
shall be provided if found necessary and when asked for.
6.17 Identification of Circuits
All switches and fuses shall be adequately labeled to facilitate the identification of the
circuits. All panels, controller and resistors are to be properly marked for each motion.
All main and control wires shall be ferruled at both ends, as per drawing for quick
identification. All elements of the controller and panels are to be clearly marked by
furnishing functional nomenclature at the devices. All equipment terminals shall be
numbered and tagged.
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If specified, one or more track switches shall be fitted to the bridge to give warning of
approach to a danger area. They shall be operated by suitable devices to be fixed to the
crane gantry as required and shall either operate an audible warning signal or trip the
main circuit-breaker on the crane, as specified in Appendix B. Track switches shall be so
arranged that they can be readily tested. Strikers shall be so arranged as to prevent
damage of the limit switch on over travel due to impact.
6.19.3.3 Proximity sensing / Anti-Collision devices
If specified, one or more devices shall be fitted to the bridge of the crane to give warning
of the approach to danger, or another crane. Anti-collision devices are relevant to safety.
Their failure will result in high impact forces, which may cause damage to the loads
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- on anti-friction bearings or runners which form a link between large parts of the
frame (for example: slewing rings, travel runner)
When necessary, safeguarding against the effects of lightning should be carried out e.g by
following IEC 61024-1.
For the safety of personnel, it is recommended that the runner rails for the lifting
equipment are earthed.
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Typically with a convention crane using Slip ring motors, one Inching is considered as
25% thermal equivalent of a start and one plugging braking is considered as 80% thermal
equivalent of a start.
With VFD fed motors, the motor manufacturers should define intermittent S3 ratings for
25%, 40% and 60% CDF. The number of operations per hour (or starts per hour) factor
can be neglected due to the soft start feature of the electronic controller, thereby
restricting the starting current and the starting losses. However it is left to the motor
manufacturer to define these ratings according to their own design.
If the required torque diagrams are not available to define the mean equivalent torque
(RMS), the values mentioned in table 5.8.3.2 a can be assumed to carry out the
calculations.
In any case the mechanical computed kW must be the minimum motor rated kW.
When the motor is fed from electronic based power control, the motor selection has to be
made in consultation with the motor manufacturer taking into account the following
factors:-
- Motors fed from VFDs can deliver higher power compared to the S1- rating
when operated on intermittent S3 duties. It is recommended that the motor
manufacturers should publish the motor ratings at the various different CDF
factors, i.e 25%, 40% and 60%. These should be considered for the optimum
selection of the motor.
- Special insulation system for high dv/dt (typically available from VFDs)
- Insulated bearings for frame size > 280 / 315 is recommended for protection of
the motor against bearing currents arising due to the shaft induced voltage due
to high frequency waveform.
The following shall be considered when two or more mechanism drive the same motion.
- The static and dynamic synchronisation of the motions according to the needs of
the application.
- Necessary interlocks between the mechanisms to ensure safe operation.
- Both the static and dynamic asymmetrical loading of the mechanisms needs to
be carefully considered and the adequate dimensioning of the motors and other
drive components.
6.20.2 SELECTION OF MOTORS FOR HOIST MOTION
For hoisting motor the power required shall not be less than that computed from the
following:
M XVXC C 1
kW = V df
X
6 .1 2 X E C am b
Where dc rating factor will be taken as 12 percent.
kW = one hour power rating for dc motors and power rating
M = mass of the rated load on the hook plus weight of the hook block
and the wire ropes in tones.
V = specified hoisting speed in M/min or actual gear box output speed
which ever is higher.
E = combined efficiency of gears and sheaves
= (0.93)n x (0.98)m for sleeve bearings
= (0.95)n x (0.99)m for anti-friction bearings (for spur and
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Table 20 B Recommended Cyclic Duration Factor and Starting Class (Clause C.1)
Duty cycle Recommended Starting class
Mechanism number cyclic duration ©
class of cyclic class © factor percent equivalent
cycles/hour starts/hour
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percent
Upto 5
M1 25 90
Cycles 25
Upto 5
M2 25 90
Cycles 25
10 Upto 15
M3 25 150
Cycles 40
16 Upto 20
M4 25 150
Cycles 40
21 Upto 30
M5 40 300
Cycles 60
31 Upto 40
M6 40 300
Cycles 60
41 Upto 50
M7 60 300
Cycles 100
51 Upto 60
M8 60 300/600
Cycles 100
It is assumed that the drive mechanism from the motor to the track wheels will used
enclosed gearings mounted on anti-friction bearings. The actual efficiency of the drive
will be adopted in making calculations. Where actual efficiency values are not available
the efficiency of the drive shall be taken in the range of 0.85 to 0.9. For the track wheel
with anti-friction bearings the rolling friction at these bearings plus the friction between
the track wheels with an average drive efficiency of 0.875 will give an overall friction
factor of 8.0 kgf per tonne of the mass moved for calculation of the motor horse power or
torque. In the case of wheels with the plain bearings an overall friction factor of 13.0 kgf
per Tonne of the mass moved may be used.
For bridge travel or trolley traverse the power of the motor required shall not be less than
that computed from the following:
M XVXSXC ⎡ 1100 Xa ⎤
kW = df
⎢⎣ F + for indoor cranes
6117 XT 9 8 1 X N ⎥⎦
M X V X S X C df ⎡ 1100 Xa ⎤ Rw XV
kW = ⎢⎣ F + 9 8 1 X N ⎥⎦ + 6 1 1 7 X T for outdoor cranes.
6117 XT
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Where
kW = one hour power rating for d.c motors and power rating at 40 percent cyclic
duration factor for a.c motors.
M = mass of crane or trolley plus mass of max rated load in tones;
V = specified free running speed M/min or actual gear box output speed which
ever is higher.
N = mechanical efficiency of gearing. For spur and helical gears it can be taken
as 0.95 per reduction.
T = factor introduced by the permissible motor torque during acceleration
exceeding the motor-rated torque.
= 1.7 for a.c Slip Ring Induction motors
= 1.3 for d.c motors
= 1.6 for a.c motors , fed from DOL
= 1.5 for a.c motors when operated from VFDs
F = over all friction factor
= 8 kgf per tonne for wheels on anti-friction bearings
= 13 kgf per tonne for wheels on plain bearings
C df = duty factor as defined in 7.4.3
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Troley Service
Factor
Without
With plugging
plugging
0.95 1.00 1.06
NOTES
1 Duty cycle, recommended cyclic duration factors and recommended starting
Class for the mechanism class can be taken from Table 20B.
2 At free running speed the acceleration becomes zero.
3 The gear reduction ratio actually used should be reasonably close to the ideal
reduction ratio:
Motor rev/min at free running
=
Track wheen rev/give specified running speed
4 In order to limit the acceleration to the specified value and also to take full
advantage of the service factor the electrical control should be designed to suit
the values of ‘S’ and ‘T’ actually adopted or values of ‘S’ and ‘T’ should be
selected based on electrical controls to be provided.
5 Since the wheels must transmit all acceleration forces to the crane, to prevent
wheel skidding due consideration should be given on percent driven wheels
after acceleration rate has been fixed. The wheel skidding should be checked
at no-load conditions considering 20 percent adhesion between wheel and rail.
6 The skewing force arising during the running of the crane needs to be
considered by the designer while designing / configuring the electronics
controls. This is usually a function of the ratio of span to the wheel base.
7 The gradients of the track and the necessary forces for CRD fed cranes has to
be taken into consideration when designing the Travel motor.
8 The horizontal forces arising due to the swaying of the load also needs to be
considered for designing of the motor especially for a high load inertia.
Table
Indications for the number of cycles per hour and the cyclic duration factor for the
vertical motions.
Particulars
Concerning Number
nature of of cycles
Type of appliance Type of mechanism ED%
use per hour
(1)
Refe- Designation Lifting Derricking Derric
Rence hinged king
boom boom
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Doc:ME 14 (0916)c
1 Hand-operated
(=not motonsed)
appliances
2 Erection cranes 2-25 25-40
3 Eraction and 2-15 15-40
dismantling cranes
for power stations,
machine shops, etc.
4 Stocking and Hook duty 20-60 40 S2 (2)
reclaiming 15-30
transporters min
5 Stocking and Grab or 25-80 60-100 S (2)
reclaiming magnet 15-30
transporters min
6 Workshop cranes Grab or 10-50 25-40
magnet
7 Overhead traveling 40-120 40-100
cranes, pigbraking 60
cranes Scrapyard
cranes
8 Landle cranes 3-10 40-60
9 Soaking pit cranes 30-60 40-60
10 Stripper cranes, 30 60
open-health 10 60
fumace-charging
cranes
11 Forge cranes 6 40
12 a) Bridge cranes a-Hook or 20-60 40-60 S (2)
for unloading, spreat duty 15-30
bridge cranes min
for containers. b-Hook duty
b) other bridge 20-60 40-60 S (2)
cranes (will 15-30
crab and/or min
slewing
13 Bridge cranes for Grab or 20-80 40-100 S (2)
unloading, bridge magnet 15-30
(with crab and /or 60 min
slewing jib crane)
14 Drydock cranes, Hook duty 20-50 40 40
shipyed jib cranes,
jib crarens for
dismanting.
Table
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Doc:ME 14 (0916)c
Indications for the number of cycles per hour and the cyclic duration factor for the
vertical motions.
Particulars
Number
Concerning
of
nature of
Type of appliance cycles Type of mechanism ED%
use
per hour
(1)
Refe- Designation Rotation Crab Travel
Rence
1 Hand-operated
(=not motonsed)
appliances
2 Erection cranes 2-25 25 25- 25-40
40
3 Eraction and 2-15 25 25
dismantling
cranes for power
stations, machine
shops, etc.
4 Stocking and Hook duty 20-60 15-40 40- 25-40
reclaiming 60
transporters
5 Stocking and Grab or 25-60 40 60 15-40
reclaiming magnet
transporters
6 Workshop cranes 10-50 25- 25-40
40
7 Overhead Grab or 40-120 40- 60-100
traveling cranes, magnet 60
pigbraking cranes
Scrapyard cranes
8 Landle cranes 3-10 40- 40-60
60
9 Soaking pit 30-60 40 40- 40-60
cranes 60
10 Stripper cranes, 30 40 60
open-health 10 40 40
fumace-charging
cranes
11 Forge cranes 6 100 25 25
12 c) Bridge a-Hook or 20-60 15-40 40- 15-40
cranes for spreat duty 60
unloading,
bridge cranes b-Hook duty
for 20-60 25-40 25-40
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Doc:ME 14 (0916)c
containers. 40-
d) other bridge 60
cranes (will
crab and/or
slewing
13 Bridge cranes for Grab or 20-80 40 40- 15-60
unloading, bridge magnet 100
(with crab and /or
slewing jib crane)
14 Drydock cranes, Hook duty 20-50 25 40 25-40
shipyed jib
cranes, jib crarens
for dismanting.
15 Dockside cranes Hook duty 40 25-40 40 15-25
(slewing, on
gantry, etc.), 20
floating cranes
and pontoon
derricks
16 Dockside cranes Grab or 25-60 40-60 25-40
(slewing, on magnet
gantry, etc.),
floating cranes
and pontoon
derricks
17 Floating cranes 2-10 15-40
and pontoon
derricks for very
heavy loads
(usually greater
than 100)
18 Deck cranes Hook duty 30-60 40
19 Deck cranes Grab or 30-80 60
magnet
20 Tower cranes 20 40-60 25 15-40
21 Derricks 10 25
22 Railway cranes 10 25
allowed to run in
train
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Doc:ME 14 (0916)c
Hold at 15 percent
rated current --
Potentiometer Lift at 40 percent --
control rated current.
Hold at 15 percent
rated current --
Shunt *Lift at 85 percent
rated voltage. *Lift at 85 percent
rated voltage
*Hold at 50 percent *Hold at 50 percent
rated voltage rated voltage
*This list intended to apply with hot coils corresponding to the duty cycle at
rated voltages. The temperature rise of the brake magnet shall not exceed that
allowed for the control equipment fitted.
6.21.1.2 Controllers
Controllers shall be rated to comply with IS 8544 (Part 1 to 4). Controllers shall be
suitably protected to prevent accidental contacts with the live parts. Controllers in ‘off’
position shall open all supply lines of the respective motors, unless otherwise agreed to,
in which case a warning notice shall be fixed to the controllers. On or adjacent to each
control device, there shall be a clear marking identifying the motion controlled and the
direction of movement.
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insulation, should be separately earthed. The surface of the housing must be a vivid color.
For indoor operation, the degree of protection should be at least IP43, and for outdoor
operation at least IP55. Pendant control units shall be suspended with a strain relief
arrangement.
- Pendent switches
The pendant switches shall be capable of withstanding rough handling without being
damaged and the cover shall be effectively secured. If control is from the floor, the
electrical control circuit to the pendant shall be energized at not more than 110V dc or ac
supply.
- Pendant control
On all pendant controlled cranes means shall be provided to prevent inadvertent operation
from the floor while maintenance work is being carried out on the crane. An isolator
fitted on the crane bridge, which can not be operated from the floor will comply with this
requirement.
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Doc:ME 14 (0916)c
that the motion can be selected by feel and the operator’s vision remain on the load.
Modular construction shall be preferable for easy replacement.
d) Typical frequencies used for radio controls are in between 450-470 MH for which
license is required. The recommended crane controls for operating are of maximum 250
metre range.
Radio crane control transmitter lever arrangement are of four motions, namely, are given
below:
Radio crane control transmitter lever arrangements are of three motions, namely, are
given below:
5. If more than one crane are provided with this type of controls, only the intended
crane and its motion is operated at one time. The transmitter shall be constructed
so that it is capable of withstanding rough handling.
Remote control may be by means of radio or infrared transmission or an off-crane control
station connected to the crane through wiring. The control station may consist of
pushbuttons, master switches, computer keyboards or combination thereof. For definition
of remote control, see the applicable ASME standards. The selection and application of
the remote control system shall be done to assure compatibility between the remote
control and the crane control system and eliminate interference. When more than one
control station is provided, electrical interlocks shall be included in the system to permit
operation from only one station at a time. Electrical interlock is defined as effective
isolation of the control circuits with the use of rotary switch contacts, relay contacts or
with the use of a programmable logic controller and its input/output modules. Due
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Doc:ME 14 (0916)c
6.21.6 Resistors
6.21.6.1 General
Resistors shall be adequately protected to prevent accidental contact with live parts.
Resistors shall be rated such that the temperature does not exceed the limits specified in
the relevant Indian Standard specification, during the operation of the crane under service
condition. The resistance and the current capacity of the resistors shall be computed
according to the actual torque requirements of the motion served and not on motor size
which may be set by thermal requirement.
The effect of using plugging as a service brake shall be taken into account in determining
the size of resistors.Resistor shall be rated according to the service conditions and the
class of crane as specified by customer.
6.21.6.2 Fittings
Resistors shall be enclosed in well-ventilated housings and, wherever necessary, be fitted
with suitable covers. Resistors shall be mounted on frames and protected and arranged in
such a way that the boxes can be easily replaced. Frames shall be of steel and shall be
built to withstand mechanical forces imposed by the crane under service conditions. The
connections to resistor terminals should be accessible and should have provisions for
adjustment.
Resistor elements shall resist corrosion and shock.
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Doc:ME 14 (0916)c
400 percent of the drive rated current. Solid state overload protection may be used
subject to the agreement of the purchaser. Preferably thermal overload protection
to be used instead of magnetic overload relays as the thermal overloads have a
reset time which would prevent the drive from restarting back immediately.
e) Switching-off of reversing contactors shall be done at near zero current. This is to
be done by ensuring that the stop/tripping command first inhibits the thyristor
controller and then switches ‘off’ the reversing contactors. This requirement will
not be applicable if the reversing is through thyristors.
f) In the case of overloading or the single phasing of the synchronizing supply, the
circuits shall be tripped immediately.
g) Whenever armature reversal (in case of the dc drive) or stator reversal (in case of
the ac drive) is to be done through the reversing contactors, the drive shall be
protected against the free fall conditions at the time of switching on and reversals
by having the preferred switching state of the reversing contactor. The drive
controller shall have suitable provisions for preventing load drifts at the time of
start and stop.
h) For achieving smooth acceleration of the drive mechanism suitable ramp
generator circuit shall be available with the controller.
i) Wherever necessary, suitable de-ration would be considered for a.c / d.c motors in
consultation with the thyristor controller manufacturer and the motor
manufacturer.
j) The control circuits shall be so designed that the brakes are applied at around the
zero speed.
k) Test points shall be available in the cards.
l) In case of wide deviation of the speed in actual value from the set value, the
circuit shall trip the mechanism immediately. During acceleration or deceleration
period such tripping shall be prevented by adjustable time setting.
m) Thyristor control shall be suitable for operation at vibration levels and
environments encountered in the crane operation.
n) If specially required by the purchaser, the drive motor shall be protected against
overheating by means of thermistors embedded in the motor winding. Matching
thermistor for trip relay shall be provided by in the control panel. The embedded
thermistors are best for preventing overloads and subsequent overheating of the
motor as these thermistors give the correct thermal image of the motor
irrespective of the current carried.
o) Wherever a.c phase controllers are to be paralleled for load sharing, the converter
outputs shall be paralleled only at the load end and not at the converter end.
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Doc:ME 14 (0916)c
b) To prevent excessive wear and tear of the commutator, the ripple content of the dc
output shall be minimized by providing smoothening chokes of sufficient
inductance depending upon motor design.
c) In case of the quadrant drives, to protect against inverter commutation failure
during regenerating mode, branch thyristor fuses shall be used. However, where it
is not possible to use branch thyristor fuses, there shall be at least one fast acting
semiconductor fuse on the dc side of the converter in addition to the semi-
conductor fuses on the ac side.
d) While switching on the system, the following sequence shall be adhered to:
- Synchronizing supply is switched ‘ON’
- Field circuits are established, and
- ac/dc contactors are switched ‘ON’.
e) The drive shall be protected against field failure with suitable circuits.
f) The field current shall be reduced to a safe value during the crane idling time to
reduce the heating of the motor. The normal field current shall resume at the start
of the drive operation.
6.22.2.3 Thyristor controllers for Slip ring motors
The thyristor controller should be a dedicated controller for crane application. It should
be with Microprocessor based closed loop, thyristor controlled adjustable AC voltage
control. The current rating of thyristor drive shall be selected corresponding to F.L.
current at electrical kW. Rating of each thyristor (ie. Itan ) shall be minimum 0.45 times
Irms. The current rating of Rotor contactors and Resistance grids shall preferably be about
125 % to 150% of rated current (depending upon minimum speed required to achieve)
which may be confirmed by thyristor drive manufacturer. The thyristor controller should
be rated at maximum of (+) 65º C and should be operational for a supply voltage
variation of –15% to (+)10%.The commissioning and trouble shooting should preferably
be done through the in-built key pad on the drive for ease of operation and maintenance
in Steel plant cranes. If possible the Key Pad should be detachable type with provision to
store the drive data sets and parameters, allowing User flexibility to upload / download
data. However provision for programming / trouble shooting from LAPTOP / PC should
also be available.
6.22.2.4.1
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When asynchronous motors are fed from VFDs , the speed can be changed by changing
the frequency of the supply (to the motor) . Up to, the base speed / frequency of the motor
(50 Hz) , the constant flux is maintained - thereby allowing the motor to deliver constant
torque through out the range from 0-50 Hz. The complete Pull Out Torque of the motor is
available at the time of starting. The normal Torque speed characteristics of the motor (at
50 Hz) shifts towards the origin with the lowering of frequency. In the field weakening
region above the nominal motor speed / frequency , the motor’s rated torque decreases
proportional to the increase of frequency and the maximum torque (Pull Out Torque)
decreases inversely proportional to the square of the speed.
Note:
If the motor is loaded up to the Pull Out Torque or too close to it , there is a risk of
getting into an unstable situation. It is recommended to use 30% margin on the P.O.T
when selecting the motor for the maximum torque requirements.
c) VFDs should always be selected based on the current rating (rated current)
mentioned in the manufacturer’s catalogue. In case of dual rating of current
mentioned in the catalogue, the current rating corresponding to “Constant Torque”
or “Heavy duty” should be selected for Crane applications.
d) The continuous current rating of the VFD shall be at least equal to the motor
current at the highest speed maintaining torque. The current required by the motor
at any foreseen loading, including dynamic situations shall not exceed the short
time rating of the VFDs.
e) The squirrel cage motors shall be of inverter duty. These motors may not be
suitable for DOL starting, hence same shall not be used for direct online starting
with bypassing VFDs.
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Doc:ME 14 (0916)c
g) VFDs shall be provided with proper branch circuit protection on the line side.
h) Distorted waveforms on the line and/or short circuit current may require the use of
Line Reactors, isolation transformers or filters.
i) Line contactor shall be used with VFDs for hoisting applications to disconnect
power from drive in case of overspend or fault.
j) A minimum of two collectors for each runway conductor shall be furnished with
inverter use.
k) The cranes using VFD controls shall adhere to the crane safety standards
mentioned by IEC 60204-32
For the Hoisting motion, the braking occurs when the load is lowered . The braking
resistor of a hoisting drive shall be selected considering the possible lowering height of
the load being lowered at the maximum speed. The calculated regenerative energy and
the lowering time can be used for designing the Braking resistor.The Hoisting drive
should preferably have the flexibility of connecting external Braking units (IGBT based)
along with the resistors.For horizontal motions, the braking resistor shall be capable of
absorbing the regenerative energy during deceleration of the motion also taking into
account the possibility of a swinging load and the wind push (the load and load
attachment included)The braking resistor shall be thermally capable to absorb the
generative energy during successive drive cycles of the application.
NOTE: The braking resistor is usually connected to the DC-bus of the inverter and due to
this it becomes live always when electric power is supplied to the inverter – also during
not running the motor.
6.23 BRAKING
6.23.1 ELECTRO MECHANICAL BRAKING
6.23.1.1 General
Brakes shall be provided for each drive. At least one brake shall be mounted on the input
pinion shaft of the gear train.Cranes, which require particular safety, e.g. in steel works or
with dangerous or melted loads, should be provided with a second brake.The operation of
the second brake shall be arranged according to the design of the drive. It is
recommended that under normal operating conditions, the second brake is always be
applied on stopping, after the motion has been brought to a halt by the main brake. In
some applications –for example if waiting for the releasing of the second brake would
cause unacceptable time delay at each starting – it may be necessary to apply the second
brake only when the crane switch (main contactor) is de-energized.In the event of an
emergency stop, the second brake should be applied immediately.
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Electro-mechanical brake/brakes used for hoist motion shall apply automatically when
the power supply fails or when the circuit brake is opened or when the controller handle
is brought to the ‘off’ position. For hoists not handling molten metal and having single
drive only the minimum braking torque shall be 150 percent of computed full load torque
when the brake is fitted. When two brakes are fitted each shall have braking torque not
less than 100 percent of the computed full load torque. Hoists handling molten metal shall
have two brakes on each drive and each brake shall have minimum braking torque of 125
percent of computed full load torque.For dc-cranes having series motors when two brakes
per motor are used, brakes will also be series brakes and connected in series. For ac-
cranes when two brakes per motor are used, the second brake may be fitted with a time
lag in which case the braking torque shall not be less than 125 percent of the computed
full load torque for each brake.
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The brake shall operate at the voltage and current values specified in Table2. Shunt
magnets shall meet the requirements when the coils are at a temperature which
corresponds to energization under rated conditions.
The temperature rise of coils shall not exceed that permitted by relevant Indian Standard
for the class of insulation employed.
Note: Brake Surfaces: The rubbing surfaces of brakes shall be smooth and free from
defects. The temperature attained by the rubbing surfaces under service conditions shall
be such that their operation is not impaired.
C FLOOR CONTROL:
C. Within Control features:
C 1 Control circuits:
If the mains supply is ac and the control circuits are supplied at reduced voltage, the
supply to these circuits shall be from the secondary winding of an isolating transformer or
an isolating transformer and rectifier. The transformer frame and one pole of this supply
shall be earthed and the contactor and relay coils shall be connected to this pole. An
earthed screen shall be provided between the primary and secondary winding. The
primary winding and unearthed pole of secondary winding of the transformer shall be
protected by fuse in line connection. Effective means shall be provided to prevent mal-
operation owing to short circuits or earth faults.
C 2 Rectifiers:
On ac cranes, if dc supply is required, rectifiers shall be provided for supplying the
control circuit, brakes and magnets. These rectifier units shall be of adequate capacity to
supply the full dc loads required continuously. They shall be of suitable construction and
mounting to withstand heat, dust, shock and vibration. Silicon type rectifier units shall be
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C4 Braking controls:
When an electro-mechanical brake is used as an emergency or parking brake or when
such an emergency or parking brake is used with hand or foot operated travel service
brakes, the brake actuating device shall remain in the circuit when the main ckircuit
breaker is closed. The brake shall apply automatically when the power supply fails or
when the circuit breaker is opened or on operating an emergency stop push button or
switch; but not when the controller handle is brought to the ‘off’ position. The brake shall
lift off when voltage at the coils is a minimum of 85 percent of rated voltage. Provision
shall be made for emergency application of this brake by means of the emergency stop
push button or switch. In the arrangement of connections to the hoisting motion brake
coils, means shall be provided to ensure that when associated drive motors are de-
energized, the stores electrical energy in these motors will not delay the application of the
brake.
C 5 Acceleration control:
Automatic control of acceleratxion shall be provided for all crane motions, unless for any
motion another control system is specified. The hoist motion circuits shall enable any
load to be lowered with safety and the hoist motors shall remainunder effective control
with the controller in all positions. While calculating the number of rotor contactors, peak
accelerating/decelerating torques and pull out torque of the motor should be taken into
account.
For creep lowering speed on hoisting motion, relatively flat speed control shall be
provided. Peak accelerating/decelerating torque shall be considered as minimum 180%
of full load torque for crxanes under M6-8 mechanism class.
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a) A circuit for portable lighting, if the ambient lighting is not sufficient to carry out
maintenance.
b) A circuit for portable tools according to agreement between customer and supplier.
c) These circuits should be protected by a differential circuit breaker of high sensitivity
and them
shall be independent of the principal circuits of the hoisting appliance.
6.24.4 LIFTING MAGNETS & LOAD HOLDING DEVICES
6.24.4.1 General
The requirements given in this clause apply to all load holding devices such as lifting
magnets and vacuum lifters. Load holding devices are normally designed for a cyclic
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Doc:ME 14 (0916)c
duration factor of 50 %. Other cyclic duration factors should be agreed between the
manufacturer and user.
The tear-off force should be at least twice the lifting capacity. If there is a stand-by
power supply from batteries, the holding time should be atleast 20 minutes. In this case,
an automatic charging unit and a charge level indicator should be provided. Use of the
stand-by supply should be indicated visually and audibly for general warning. If the
battery voltage level is not adequate, a device preventing the installation from being used
should come into effect. If required by the purchaser, the crane shall be fitted or
provision shall be made to permit in the future fitting of lifting magnets, magnet control
and protective gear.
6.24.4.2 Magnet
The type and size of magnet shall be decided based on the details given by the purchaser.
The type and size of magnets shall preferably be in accordance with details specified in
Appendix B.
Each magnet will be water tight and shall be provided with a water tight terminal box
having the under mentioned features, however rectangular magnets are normally of
fabricated construction type also can be used as follows:
a) Integral construction with magnet casing,
b) A gland through which the magnet load is brought to the magnet terminals
c) A cover which shall be easily removable without interfering with the magnet lead inlet.
d) Adequate thickness of box and cover, and
e) Non-linear type discharge resistor of adequate rating and the rectangular magnets are
fabricated constructions and nice fabricated type of magnets.
6.24.4.3 Magnet Lead and Cable
The magnet lead and cable shall be flexible three core cables. If specified by the
purchaser, the magnet lead shall be protected by rubber hose complying with the relevant
Indian Standard. The magnet lead shall be so arranged that it does not become unduly
slack or taut during normal operation of the crane. It should be so located that magnet
cable does not foul with the rope. The use of sheaves and rollers for the cable should be
avoided as far as possible. The magnet cable shall be rigidly attached to the bottom block
by a suitable cable clamp at a point above magnet coupling.
6.24.4.4 Magnet couplings
The type of magnet coupling shall be as agreed between the purchaser and the cane
supplier. The coupling shall comply with the following requirements:
a) The couplings shall be of rugged construction,
b) At the moment of breaking, the contacts shall be enclosed by insulating material and
earth connection shall break last,
c) Provision shall be made to fasten the coupling in the closed position.
d) The socket shall be connected to the supply and plug to the magnet or magnet lead.
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Doc:ME 14 (0916)c
c) Capable of accommodating and paying out the length of cable necessary for the
magnet to reach its lowest position.
Cable drum when attached to the hoist drive, a disengagement device shall be provided.
Where power is fed to the magnet by a brush and slip ring arrangement on the magnet
cable drum, two brushes per slip-ring shall be provided and the rings shall have adequate
clearance. The slip ring insulation shall bed of non tracking material and the assembly
shall be enclosed by an easily removable cover, oil-proof for indoor cranes and weather
proof for out door cranes. A spare slip ring complete with brush gear arrangement shall
be provided if required by the purchaser.
6.24.4.6 Magnet Control and Protective Equipment
The magnet shall be controlled either by direct-online control or potentiometer control as
required by the purchaser. In both methods of control the magnet shall be demagnetized
by current reversal. In direct-on-line control, the magnet shall be energized by switching
it across full mains voltage and discharge resistance shall be connected on switching
‘OFF’. The control shall be affected by means of a master controller and magnetic
contactor panel.
6.24.4.7 Battery Back up System
If required by the purchaser, necessary and adequate battery back up system shall be
provided by the supplier. The rechargeable battery shall keep the magnet energized till
the time the lifted load is brought to a safe location, in the case of power failure. If there
is a stand-by power supply from batteries, the holding time should be atleast 20 minutes.
In this case, an automatic charging unit and a charge level indicator should be provided.
Use of the stand-by supply should be indicated visually and audibly for general warning.
If the battery voltage level is not adequate, a device preventing the installation from being
used should come into effect.
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Section – IV
7.1
Table - 13
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Table - 14
7.1.1
Table - 15
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Figure - 10
7.1.2
Table - 16
7.2
7.2.1
7.2.3
7.2.4
7.2.2
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7.2.5
7.2.7
7.2.8.
7.2.6.
7.2.9..
7.2.10
7.2.11
7.2.12
7.2.13
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7.2.16
7.2.17
7.2.14
7.12.18
7.2.15
7.12.19
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7.2.26
7.2.20
Table 17
7.2.21
7.2.22
7.2.23
7.2.24
7.2.25
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Table 18
C ifi
7.2.27
7.2.28
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Figure - 11
Table - 19
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7.2.30
7.2.31
7.2.32
7.2.29
4.1.33
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d) Adjust end limit switch trip. 7.2.39 Never lower block beyond the point at
e) Reverse master switch and repeat (a) to (d). which one wrap remains at each end of the drum.
7.2.40 Load Test
t) Reset trolley timers, if needed.
After the no-load running test has been
7.2.34Bridge Motion (Long Travel) completed, the crane should be tested with
a) Place master switch in 1st point 'Trolley travel' loads in the following manner:
position. a) Raise a load equal to about 5 percent of the
b) Observe contactor sequence and direction of rated load not higher than required to clear
travel through full range of master switch. its supports and stop adjust brake, if necessary.
Reverse phasing, if necessary. Raise load about I m above its supports and
c) Allow trolley to move entire length of bridge stop. Lower the load about 300 mm and stop.
span, are fully watching alignment of trolley Check drift of load during stopping.
collector pole and bridge conductors and also If load drifts, brakes are not in proper
watching for any interference with building and adjustment and should be corrected. Repeat
building equipment. Do not run trolley into end this operation until proper adjustment of brakes
stops. is obtained. Lower load carefully back to its
supports.
d) Adjust end limit switch trip.
b) Load the hoist motion with 125 percent of rated
e) Reverse master switch and repeat (a) to (d). f) capacity and follow the same procedure as
Reset trolley timers, if needed. mentioned in (a).
i) Then hoist the load high enough to clear
7.2.35 Check all Accessoriesfor Proper Function
all obstructions but not higher
7.2.36 No-Load Test than necessary. Move trolley across
the entire span of bridge. Transport the
7.2.37 After Reeving the Hoist. Test the Operation test load by means of the bridge for
of the Hoist Limit Switches asfollows full length of the runway in one
a) Raise empty blocks to within about 500 mm . of direction with the trolley at the
its upper position and stop. extreme right hand end of the crane,
b) Raise the empty block at the lowest control and in the other direction with the
speed until the limit switch trips and stops the trolley at the extreme left hand end of
hoisting motion. During this operation watch the crane.
for proper alignment between load block and ii) Measure the deflection when the trolley
limit switch trip. with test load is at the middle of the
girder and at extreme end of the
c) Check that block stops at correct height as
girder. Check whether the deflection
shown on drawings. Adjust limit switch, if
necessary. is within the allowable limit.
iii) Measure the 'No-Load' and 'Full Load'
d) Lower block to 1.5 m. current of the motor and verify whether it is
e) Raise block at about half speed. as per.the recommendations of motor
manufacturers.
f) Check for adequate clearance between Check the resistors in the circuit whether
block and trolley frame (or upper sheaves) any over-heating of the element occurs.
iv) If separate creep speed control is provided
g) Repeat points (d), (e) and (1) with block it should be run for check-out over a
being raised at full speed. distance of about 500 mm
v) Check overload relays for proper function
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A-I. This specification applies to the following types of cranes and special service machines. ( The list is
not exhaustive ):
d) Pig machine.
e) Ladle cranes used in the charging and/or tapping of hot metal mixer vessels, Bessemer
converters of LD vessels, open hearth and electric furnaces, etc.
f) All cranes and machines (either floor mounted or running on over-head gantries) used to cold
charge open hearth or electric furnace, etc, or used to charge and draw all types of reheating
furnaces.
g) Bucket handling cranes at various raw and scrap material stock yards, crab cranes and bridges
handling, coal, ore, limestone, etc, or by-product or waste materials, such as slag, cinder and
mill scale.
h) Magnet cranes used for skull cracking, and for handling and preparing steel scrap.
i) Magnet and cradle cranes for handling semi-finished steel (such as slabs, blooms and billets)
and for stocking and shipping finished products (such as structurals, rails, plates and sheets)
in the various mills and departments.
k) Ingot and ingot mould handling cranes at stripper yards, ingot stock yards and soaking pit
buildings, etc.
m) MiIl building cranes for changing stands and rolls in the various mills.
NOTE -- This code is not intended for application to those cranes within the confines of a steel
plant which are ancillary to the plant production processes. It is recommended that these
cranes should be designed and manufactured in accordance with the appropriate classificaticn
in IS 3177/1999.
n) Cranes and repair trolleys on fixed high level gantries for the servicing and repair
of furnaces or of ladle cranes or s:ripper cranes, etc.
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APPENDIX B
INFORMATION TO BE SUPPLIED WITH THE ENQUIRY OR ORDER
B-O. The purchaser shall specify his requirements by tilling in certain portions of the following proforma
as indicated under each section heading. The other portions refer only to additional requirements and need
only be completed where these are specifically requil ed, and should be crossed if not deemed necessary.
Where the purchaser is unable to fill in any particular portion, the requirement should be made
the subject of agreement between the purchaser and the manufacturer, and the purchaser should
state this in the relevant paragraph.
B-1. GENERAl,
B-1.1 Number of cranes:.................................
B-1.2 Duty or class of crane: .......................... ,...
a) Crane structure ( see 5 of IS : 807-2006 )
b) Main hoist
c)' Auxiliary hoist
d) Cross-traverse
e) Long-travel
*Code of practice for design of overhead travelling cranes ar.d gantry cranes other than
steelworks cranes ( first revision ).
t
Code of practice for design, manufacture, erection ar:d testing structural portion) of
cranes and hoists (first revision ).
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Fig.12
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B-3. STRUCTURAL DETAILS (See Fig. 12)
B-3.1 Distance Between Centre Lines of Gantry or Track Rails (S)
.. . .. . .. . .. . .. . .. . .. . .. . .. . .. ….. .. .. . .. . .. . .. . .. . .. . .. . . .. . .. .. . .. . .. . .. . .. . metres ( span)
NOTE - It is recommended that the span of the track shall not vary by more than ±12
mm. When the track span does not satisfy this requirement the maximum and
minimum span for which the crane has to be designed shall be specified by the
purchaser.
B-3.2 a) Side clearance - Distance from centres of gantry or track rails to nearest side:
1)…………………………………………………………(Al) metres
2) (A2 ) metres
b) Distance from top of gantry rail to:
1) Lowest overhead obstruction (C).................... …….. .metres
2) Floor level (D) .......................................................... ..metres
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B-5.1 General
a) Type of long travel drive...................................................
b) Make and type of flexible couplings ............,................
c) Type of any overload slip device (fluid coupling, plate-clutch,
or cone clutch)...............................................................
B-5. MECHANICAL DETAILS
B.5.2 Type of Hooks:
a) Main hoist... ... ... ... ... ... ... ... ... ... ... ... …………………………….
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B-6.2 Braking
Any requirements for:
a) electromechanical shunt brake(s) on hoist motion(s)............
b) emergency brake(s) on hoist motion(s) of moving cab cranes. ( electromechanical
shunt, mechanical or hydraulic )..............
c) emergency electro-mechanical shunt brake(s) on:
1) the
... ....hoist
... .. ... ..motions
. .......... .... .of
.......fixed
. .. . ..cab
. ..cranes..............................
. .. . . .. . .. .. . .. . .. . .
2). ..the cross-travel motion(s) of moving cab cranes...............
B-6.3 Motors
a) Manufacturer of main motors: ........……………………………….
c) Class of insulation of main motors.........................................
d) dc-mill motor details (if not selected from any standard specification)
Table - 20
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ANNEX C (Clause – 44)
For hoisting motor the power required shall not be less than that computed from the
following:
where
kW = one 'hour power rating for dc motors and power rating at (S - 40 percent) cyclic
M = mass of the rated load on the hook plus weight ofthe hook block and the wire ropes in tonnes,
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IS 3177: 1999
1 100a ' Rw V ' Table 25 Acceleration Values
kW= MVSCdf' , F+ ,, +-- for
6117T 98IN' 6117T
( }
out door cranes
Speed, Condition
where Acceleratio
to be Acceleration Acceleration
n
kW = one hour power rating for d,c. motors and Reached in cm/s2 in cm/s2 for in cm/s2 for
power rating at 40 perent cyclic duration M/min Low and Moderate High Speed
factor for a,c. motors; Moderate and High with High
Acceleratio
Speed with Speed
M = mass of crane or trolley plus mass of max n
rated load in tonnes; Long Travel (Normal
Application)
v = specified free running speed M/min; 240 - 50 67
N = mechanical efficiency of gearing. For spur 190 - 44 I 58
and helical gears it can be taken as 0.95 150 - 39 J 52
per reduction; 120 22 35 47
T 100 19 32 43
= factor introduced by the permissible motor
torque during acceleration exceeding the 60 15 25 33
motor-rated torque. As a general guidance 40 12 19 -
value of T may be taken as 1.7 for motors 25 10 16 -
having pull out torque of 275 percent full
load torque. Lower values of T should be 15 8 - -
taken for corresponding lower values of 10 7 - -
pull out torque. Table 26 Values of Service Factors
= 1.3 for d.c. motors pullouttorque x 100 Bridge Service Factor Trolley Service
Factor
= 1.6 for a.c. motors 160 x fuli load torque 0.95 1.00 1.06
F = overall friction factor
NOTES
= 8 kgf per tonne for wheels on anti -friction 1 Duty cycle, recommended cyclic duration
bearings factors and recommended starting Class for the
mechanism class can be taken from Table 20B.
= 13 kgf per tonne for wheels on plain
bearings 2 At free running speed the acceleration becomes
zero.
Cdf = duty factor as defined in 6.4.3;
3 The gear reduction ratio actually used should be
RwI= load due to service wind acting reasonably close to the ideal reduction ratio:
horizontally as defined in 6.3.1 which can Motor rev/min at free running Track
be obtained by multiplying the horizontal wheel rev/give specified running speed
exposed area by the service wind by taking
drag co-efficient into consideration; 4 In order to limit the acceleration to the specified
value and also to take full advantage of the service
a factor the electrical control should be designed to
= average linear acceleration ofthe crane or suit the values of 'S' and 'T actually adopted or
the trolley in Cm/S2 till the mechanism values of'S' and 'T should be selected based on
reaches 90 percent offree running speed. electrical controls"to be provided.
For the values of average linear
acceleration refer as given in Table 2IA; 5 Since the wheels must transmit all acceleration
and forces to the crane, to prevent wheel skidding due
s = service factor aimed at providing adequate consideration should be given on percent driven
motor heat dissipation capacity as given in wheels after acceleration rate has ben fixed. The
Table 2IB. wheel skidding should be checked at no-load
conditions considering 20 percent adhesion
betwen wheel and rail.
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ANNEX D (Clause-51)
ANNEX E
CRANE-RECOMMENDED/PREFERRED PARAMETERS
E-1
GENERAL E-3 PREFERRED LIFTING HEIGHT
Preferred series R5 shall be used for lifting heights up
to and including 16m and RIO for heights above 16m.
The preferred lifting heights (in metres) are as
follows:
2.5 10 25 50
E-2 PREFERRED LIFTING CAPACITIES
4.0 16 32 63
Preferred series RIO shall be used for capacities up to 6.3 20 40 etc.
and including 125 tonnes and R20 for capacities E4 PREFERRED SPEED OF OPERATION (FULL
above 125 tonnes. The preferred lifting capacities ( in SPEEDS)
tonnes ) are as follows:
Preferred series R5 and R1O shall be used for full
1.0 3.2 10 32 100 225 400 speed of operation respectively. The preferred speeds
of operation (in metres per minute) are as follows:
1.25 4.0 12.5 40 125 250 450
1.6 5.0 16 50 140 280 500 0.63 1.6 4.0 10 25 63 160
0.8 2.0 5.0 12.5 32 8) 200
2.0 6.3 20 63 160 320 560
1.0 2.5 6.3 16 40 100
2.5 8.0 25 80 200 360 etc. 1.25 3.2 8.0 20 50 125
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IS 3177: 1999
ANNEX F
(Section II and III)
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IS 3177 : 1999
IS No. Recommendations for Title metal arc welding of IS No. carbon and carbon Title
2365 : 1977 Specification for steel wire ropes 1323: 1982 Code of practice for oxy-
manganese steels for lifts, elevators and hoists acetylene welding for structural
(first revision) work in mild steel ( second
2762: 1982 revision)
Specification for wire rope slings
and sling legs (first revision) 9595 : 1980
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IS 3177 : 1999
Title IS No. Title
IS No.
2253 : 1974 Designation for types of 3427: 1969 Specification for metalenclosed
construction and mounting switchgear and control gear for
arrangement of rotating voltages above 1000 V but not
electrical ~achines ( first exceeding 11000 V
revision)
8544 Specification for motor starters for
4691: 1985 Degrees of protection provided voltages not exceeding 1000 V:
by enclosure for rotating
electrical machinery ( first
revision) Direct-on-line ac starters
( Part 1 ) : 1977
4722: 1968 Specification for rotating Star-delta starters
electrical machines (Part2): 1977
( Part 3/Sec 2 ) : Rheostatic motor starters,
4728: 1975 Teminal marking and direction 1977 Section 2 Additional
of rotation for rotating electrical require~ents for ac rheostatic
machinery (first revision) motor controllers
12065: 1987 Pemissible lirits of noise level for ( Part 4 ) : 1979 Reduced voltages AC-starters,
rotating electrical machines two-step auto transformer starters
F-3.2 Cables and Conductors
Code of practice for selection,
9968 Specification for elastometers 10118 installation and maintenance of
insulated cables: . switchgear and controlgear:
(Part 1) : 1988 For working voltages up to and
including 1100 V (first revision) General
(Part 1): 1982
Selection
(Part 2 ): 1981 For working voltages from 33 (Part 2 ) : 1982
kVuptoandincluding 11 k V Installation
(Part3): 1982
694: 1977 Specifjcation for PVC insulated Maintenance
cables for working voltages up (Part4): 1982
to and including 1 100 V ( 13 947 Low-voltage swicthgear and
second revision) (Part 1): 1993 controlgear : Part 1 General rules
1554 Specification for PVC insulated 13118: High voltage alternating current
( heavy duty) electric cables:
circuit breakers
1991
(Part 1): 1988 For working voltages up to and
including 1 100 V (third F-3.4 Earthing
revision) Code of practice for earthing
(Part2): 1981 3043: 1987
For working voltages from 3.3 F-3.5 Conduits
kV up to and including 11 k V (
second revision) 9537 Conduits and .electrical
8130: 1984 installations:
Specification for conductors for
insulated electric cables and
(Part 1): 1980 General requirements
flexible cords (first revision)
F-3.3 Switch Gear
(Part2): 1980 Rigid steel conduits
2516: Specification for circuit breakers:
( Parts 1 & 2/ Parts 1 & 2 Requirements and (Part 3 ): 1981 Rigid plain conduits insulating
Sec 1) : 1985 tests, Section 1 Voltages not 0f materials
exceeding 1000 V ac or 1 200 dc (Part4): 1983
( second revision) Pliable self-recovering conduitsof
insulating materials
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IS 3177 : 1999
IS No. Title IS No. Title
F-3.6 Cranes 13743 Cranes - Vocabulary: Part I
International Standards:
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