1091-5 T Sgeot

OPERATION & MAINTENANCE OF SINGLE GIRDER
M/s GRIP ENGINEERS PVT. LTD. Piyala Road, P.O.: Sikri, Ballabgarh 121102. Distt. Faridabad, Haryana (INDIA)
Page 1 of 11
Ph.:- 0129 4187400 Fax:- 0129 - 4187440 E-Mail :- fbd@gripengineers.com Web:- www.gripengineers.com
PREFACE
This booklet has been compiled to assist the Executives of the Organisation purchasing GRIP make EOT Cranes and the concerned operating personnel to become familiar with the code of Signals, Operation, Maintenance and repair of the Unit purchased. You are right that you have purchased the unit from us and that you are entitled for service by us. But this does not mean that you have no responsibility in the upkeep of the unit when in service or out of service. You have spent in the purchase and installation of the unit which needs for its life, your careful and reasonable nursing. The care and operation of an Overhead Crane should be carried out in the same manner in which you would like to care your machine tool or production machinery. The need of safety is much more important for lifting devices since loads are hoisted and moved overhead. Any failure can mean monetary loss or fatal accident. The performance of the unit is related not only to the intensity of its use but is related to its care and maintenance too. Hence, proper lubrication, systematic inspection / maintenance of the mechanical parts like gears, wire rope and electrical equipment such as motors, brakes, limit switches and control gears are of utmost importance. If anything does go wrong with the machine, have it repaired at once. It is better to spend sometime in affecting the minor repairs as soon as any trouble is noted than to take a chance and run the machine until it develops serious trouble needing to idle the unit for a longer time while major repairs are being done, or until it causes an accident. GRIP EOT Cranes are quite sound and compact but yet sturdy. Serious troubles will not be experienced with GRIP lifting devices, if the suggestions proposed in this booklet are adhered to.
Page 2 of 11 M/s GRIP ENGINEERS PVT. LTD. Piyala Road, P.O.: Sikri, Ballabgarh 121102. Distt. Faridabad, Haryana (INDIA) Ph.:- 0129 4187400 Fax:- 0129 - 4187440 E-Mail :- fbd@gripengineers.com Web:- www.gripengineers.com
OPERATING & MAINTENANCE INSTRUCTION

M/S MADHUCON PROJECTS LIMITED SINGLE GIRDER EOT CRANE 5.0T X 10.5 M SPANS
Manufacturer:
M/s GRIP ENGINEERS PVT. LTD. Piyala Road, P.O. : Sikri, Ballabgarh 121 102. Distt. Faridabad, Haryana (INDIA). Ph.:- 0129 4187400 Fax:- 0129 4187440
Year of construction:
2011
Job No.: Crane Serial No.:
1091-A 1876
GA DRAWING No.: ELEC. DRAWING No.:
GEPL/1091-A/01 GEPL/1091-A-EL/02
GENERAL DISCRIPTION
SINGLE GIRDER E.O.T. CRANES
MAIN COMPONENTS THE CRANE CONSISTS OF THE FOLLOWING MAIN PARTS: BRIDGE GIRDER END CARRIAGES LONG TRAVEL MECHANISM CROSS TRAVEL MECHANISM HOISTING TACKLE
BRIDGE GIRDER ONE NO. OF BRIDGE GIRDER WELDED PLATE BOX TYPE OR RSJ COMPOUND BEAM IS PROVIDED. IT FORMS THE MAIN SUPPORTING MEMBER FOR ALL THE LIVE AND DEAD LOADS. END CARRIAGES THESE ARE THE TWO CROSS END SUPPORTING MEMBERS ON WHICH THE GIRDERS REST. THE END CARRIAGE CARRIES THE CRANE WHEELS. LONG TRAVEL MECHANISM IT CONSISTS OF: BY MEANS OF PULLING THE HAND CHAIN WHICH WILL IN TURN DRIVE THE DRIVING WHEEL. LONG TRAVEL WHEELS HELD IN THE END CARRIAGES AND RUNNING ON THE GANTRY RAILS ALONG THE LENGTH OF THE BAY.
CROSS TRAVEL MECHANISM:IT IS OF UNDER-SLUNG MONORAIL TYPE RUNNING ON THE LOWER FLANGE OF THE BRIDGE GIRDER. IT CONSISTS OF THE FOLLOWING: CROSS TRAVEL WHEELS SUPPORTED IN BEARINGS FIXED ON THE TROLLEY FRAME ARE DRIVEN BY AN ELECTRIC MOTOR THROUGH SPUR/HELICAL GEAR BOX AND C.T. DRIVE PINION. SINGLE FLANGED CROSS TRAVEL WHEELS FIXED TO THE TROLLEY FRAME RUNS ON THE LOWER FLANGE OF THE BRIDGE GIRDER ON ANTIFRICTION BEARINGS. HOISTING TACKLE:IT IS A STANDARD WIRE ROPE ELECTRIC HOIST BLOCK TYPE WITH THE FOLLOWING: TOP SUSPENSION CROSS TRAVEL ASSEMBLY. HOIST BLOCK ASSEMBLY CONSISTING OF ROPE DRUM, GEARING ARRANGEMENT, SHOE / DISC TYPE EM BRAKE AND HOISTING ELECTRIC MOTOR. WIRE ROPE LOWER HOOK BLOCK SUB-ASSEMBLY WITH PULLEYS AND SHANK TYPE HOOK ROTATING ON ANTIFRICTION THRUST BEARING. TOP EQUILISING PULLEY SUB-ASSEMBLY.
INSTRUCTIONS FOR ERECTION OF CRANES

GENERAL:THE INSTRUCTIONS GIVEN HERE FOR THE ASSEMBLY, TESTING AND COMMISSIONING OF THE CRANES SHOULD BE CAREFULLY FOLLOWED AS GOOD INSTALLATION WILL ENSURE YEARS OF SATISFACTION AND TROUBLE FREE OPERATION. FOR ERECTING THE CRANE A CLEAR SITE SHOULD BE ALLOTED. NO OTHER OPERATIONAL OR CONSTRUCTION JOB SHOULD NOT TAKE PLACE ON THIS SITE WHILE THE CRANE ERECTION IS IN PROGRESS. THE SITE DIMENSIONS SHOULD ALLOW EASY MANUPULATION OF THE CRANE AT PREPARATORY STAGE AS WELL AS DURING THE ERECTION. Page 5 of 11 M/s GRIP ENGINEERS PVT. LTD. Piyala Road, P.O.: Sikri, Ballabgarh 121102. Distt. Faridabad, Haryana (INDIA) Ph.:- 0129 4187400 Fax:- 0129 - 4187440 E-Mail :- fbd@gripengineers.com Web:- www.gripengineers.com
PREPARATORY WORK FOR ERECTION: SELECT A SPACE IN THE BAY WHERE THE CRANE IS TO BE ERECTED. THE MOST SUITABLE LOCATION OF ERECTION SITE IS IN THE SPAN IN-BETWEEN COLOUMNS. IT IS ADVISABLE TO CHOOSE A SPAN WHICH HAS NO HORIZONTAL TIES BETWEEN TRUSSES. KEEP ALL THE ERECTION EQUIPMENT SUCH AS DERRICKS, WINCHES, PULLEY BLOCKS, SLINGS, TOOLS ETC. READY BEFORE COMMENCING ERECTION. ENSURE THAT ALL THE CRANE PARTS ARE IDENTIFIED, THOROUGHLY CLEANED AND KEPT IN ORDERLY MANNER. LOOK FOR MATCH MARKS AND ARRANGE ACCORDINGLY. CHECK THE GANTRY RAILS AND ENSURE THAT THEY ARE IN PROPER ALLIGNMENT AND LEVEL. THE SMOOTH RUNNING OF THE CRANE VERY MUCH DEPENDS ON THE RAIL ALLIGNMENT. CHECK THE SPAN WHICH SHOULD BE EQUAL TO THE CRANE SPAN AND MAKE SURE THAT THE DEVIATION IF ANY SHOULD BE WITHIN THE PERMISSIBLE LIMITS. ANY ABNORMAL VARIATION MUST BE RECTIFIED PRIOR TO THE ERECTION OF THE CRANE. ERECTION OF CRANE: IN CASE THE SIZE OF THE CRANE IS SMALL AND THE SPACE AND THE LIFTING EQUIPMENT PERMITS, THEN THE END CARRIAGES AND THE GIRDER MAY BE ASSEMBLED TOGETHER ON THE GROUND AND THE COMPLETE ASSEMBLED STRUCTURE LIFTED TOGETHER AND PLACED ON THE GANTRY GIRDERS. IF THE ABOVE IS NOT POSSIBLE, THE INDIVIDUAL END CARRIAGES SHOULD BE TAKEN UP AND PLACED ON THE EITHER SIDE OF GANTRY RAILS. THEY SHOULD BE PROPERLY SECURED TO THE GANTRY GIRDERS. NEXT THE GIRDER IS TO BE ERECTED. IN CASE THE GIRDER IS HAVING A JOINT, IT SHOULD BE FIRST ASSEMBLED AND JOINED TOGETHER ON THE GROUND BEFORE LIFTING. THE GIRDER IS THEN PLACED ON THE END CARRIAGES AND FIXED BY MEANS OF TIGHT BOLTS. ELECTRIC WIRE ROPE HOIST SHOULD BE UNPACKED UNDER THE BRIDGE. LIFT THE ELECTRIC WIRE ROPE HOIST AND MOUNT IT ON THE LOWER FLANGE OF THE BRIDGE. MAKE ELECTRICAL CONNECTIONS.
OPERATIONAL INSTRUCTIONS
INSPECTION BEFORE OPERATION:CHECK THE FOLLOWING THOROUGHLY, TO ENSURE THAT THE CRANE IS FINALLY READY FOR THE TRIAL RUNS. ALL POINTS REQUIRING LUBRICATION SHALL BE WELL LUBRICATED. OPEN THE HOIST GEAR BOX COVER AND FILL THE RECOMMENDED LUBRICANT. SLIGHTLY LUBRICATE THE WIRE ROPE WITH LIGHT OIL. C.T. & L.T. OPEN GEARING SHOULD BE PROPERLY GREASED. CHECK BUFFERS AND END STOPPERS ARE PROPERLY FIXED. CHECK ALLL NUTS AND BOLTS, ESPECIALLY THE END CARRIAGE AND GIRDER JOINT BOLTS TO ENSURE THEY ARE FULLY TIGHTENED. CHECK THE GANTRY GIRDER JOINTS AND THE ANRY RAIL JOINTS AND CLAMPINGS. ENSURE THAT ALL MOTIONS ARE FREE. TRY ALL MOTIONS AT NO LOAD. RELOCATE THE END STOPPERS SO THAT THE BUFFERS ON BOTH SIDES STRIKE THE STOPPERS AT THE SAME TIME. TRIAL OPERATION:THE CRANE IS NOW READY FOR LOAD TESTING. LOAD TEST SHOULD BE CARRIED OUT AS FOLLOWS: OPERATE INDIVIDUAL MOTIONS AT NO LOAD. TAKE 25% TO 50% OF THE RATED LOAD AND OPERATE THE INDIVIDUAL MOTONS. FOLLOW THE SAME PROCEDURE WITH 100% LOAD. FOR DEFELECTON TEST POSITION THE RATED LOAD AT THE CENTRE OF SPAN, REMOVE THE SLINGS FROM THE HOOK. TAKE THE HOIST TO ONE EXTREME END. HANG A WEIGHT FROM A THIN ROPE/WIRE AND SUSPEND IT FROM THE GIRDER AT THE MIDDLE OF THE SPAN. MEASURE THE HEIGHT OF THE ONE END OF THE SUSPENDED OBJECT FROM A FIXED POINT ON THE FLOOR. NOW BRING THE HOIST TO THE CENTRE OF THE SPAN, SLING THE LOAD AND LIFT IT TO CLEAR THE FLOOR. ONCE AGAIN MEASURE THE HEIGHT OF THE Page 7 of 11 M/s GRIP ENGINEERS PVT. LTD. Piyala Road, P.O.: Sikri, Ballabgarh 121102. Distt. Faridabad, Haryana (INDIA) Ph.:- 0129 4187400 Fax:- 0129 - 4187440 E-Mail :- fbd@gripengineers.com Web:- www.gripengineers.com
SAME EDGE OF THE OBJECT FROM THE SAME FIXED POINT ON THE FLOOR. THE DIFFERENCE IN THESE TWO READINGS WILL GIVE US THE DEFLECTION OF THE GIRDER AT FULL LOAD. IF THIS IS LESS THAN SPAN/900, LOAD THE CRANE TO 125% FO THE RATED LOAD. CHECK THE CURRENTS IN EACH PHASE OF EACH MOTOR AT FULL LOAD AND ENSURE THAT IT IS LESS THAN THE RATED FLC OF CORRESPONDING MOTORS EXCLUDING RESPECTIVE BRAKE CURRENT. CHECK INDIVIDUAL MOTIONS AT OVERLOAD. IT IS NOT NECESSARY TO RECORD ANY READINGS. ONLY ENSURE THAT THE MOTIONS PERFORM WELL UNDER OVERLOAD CONDITIONS. SET THE BRAKES IF NECESSARY. THE CRANE IS NOW COMMISSIONED AND READY FOR REGULAR SERVICE.
SAFE HOISTING PRACTICES CRANES ARE DESIGNED WITH THE SAFETY OF THE OPERATING PERSONNEL FIRST IN FIND. YOUR OWN SAFETY AND THAT OF YOUR FELLO WORKERS WILL BE ASSURED WHEN THE OVERHEAD EQUIPMENTS IS USED AS PER THE RECOMMENDATONS AND INSTRUCTION OF THE MANUFACTURER. DISREGARDING SUCH RECOMMENDATIONS ENDANGERS LIFE AND PROPERTY. THE FOLLOWING ARE ABSIC RULES WORTHY OF YOUR CAREFUL CONSIDERATION AND ATTENTION. 1. DO NOT LOAD BEYOND THE RATED CAPACITY. THE IMMEDIATE DANGER IS THE POSSIBLE FAILRE OF SOME LOAD CARRYING PARTS. OVERLOADING MIGHT START A DEFECT WHICH COULD LEAD TO SOME FUTURE FAILURE EVEN AT LESS LOAD THAN RATED. 2. DO NOT USE ANY OVERHEAD MATERIAL HANDLING EQUIPMENT FOR HANDLING PERSONNEL. 3. CONDUCT A PERIODIC VISUAL INSPECTION FOR SIGNS OF DAMAGE OR WEAR.
PARTICULAR ATTENTION SHOULD BE PAID TO LONG CHAIN AND HOOK. IF THERE ARE ANY SIGNS OF WEAR OR DESTORTION OR OPENING OUT OF THE LINKS OR HOOK, BRING IT TO THE NOTICE OF THE SAFETY ENGINEER BEFORE LOADING THE CRANE. 4. DO NOT USE THE WIRE ROPE OR HAND CHAINS A SUBSTITUTE FOR SLINGS. 5. STAND CLEAR OF ALL LOADS. IF YOU TRAVEL THE LOAD OVER THE HEADS OF OTHER PERSONNELS, GIVE AMPLE WARNING OF YOUR INTENTION BEFORE YOU MOVE. 6. CENTRE THE HOIST OVER THE LOAD BEFORE LIFTING. DO NOT SIDE PULL OR END PULL. MAKE SURE THAT THE LOAD IS BALANCED EVENLY ON ROPES. 7. USE PADDING ON THE EDGE OF LOAD IF IT IS SHARP OR ANGULAR, TO PREVENT DAMAGE TO THE SLINGS. 8. REVERSING THE POSITION OF AN OBJECT ON LOAD IS AMONG THE MOST DANGEROUS TYPES OF OPERATIONS. 9. DO NOT DRAG THE LOAD AS DRAGGING CREATES HIGHER STRESSES. 10. DO NOT LEAVE THE LOAD SUSPENDED IN AIR OR UNATTENDED. 11. AFTER DISUSE:
WHEN THE CRANE IS TO BE USED AFTER A LONG PERIOD OF DISUSE, BE SURE TO OPERATE ALL MOTIONS WITHOUT LOAD FIRST.
MAINTENANCE
SERVICE LIFE AND OPERATIONAL SAFETY OF THE CRANE DEPEND ON A LARGE EXTENT ON PROPER MAINTENANCE AND LUBRICATION. NEEDLESS TO SAY, DAILY MAINTENANCE AND INSPECTION ARE NOT ONLY IMPORTANT FOR SAFE OPERATON BUT ALSO GOVERN THE EFICIENCY AND SERVICE LIFE OF CRANE. ALL DRIVING PARTS SHOULD BE REGULARLY EXAMINED FOR FAULTLESS OPERATION.
GENERAL PRECAUTIONS:THERE ARE MANY POINTS REQUIRING ATTENTION FOR MAINTENANCE OF CRANE. BUT THE MOST IMPORTANT ITEMS MAY BE BROADLY CLASSIFIED AS FOLLOWS:1. LUBRICATION:LUBRICATION, WHICH IS AN IMPORTANT TO A CRANE AS BREATHING TO A HUMAN, MUST NEVER BE FORGOTTEN. FILL THE PROPER AMOUNT OF OIL OR GREASE AT INTERVALS AS RECOMMENDED. LUBRICANT MUST BE CLEAN AND STORED IN DUST TIGHT CONTAINERS. 2. WORNOUT OR DEFORMED OR BROKEN PARTS:IF THE WEAR ON DEFORMED PARTS IS WITHIN A SPECIFIED LIMIT, THE PART CAN STILL BE USED. AT EACH PERIODIC INSPECTION, CONSIDER THE AMOUNT OF EXPECTED WEAR BEFORE THE NEXT INSPECTION AND REPAIR OR REPLACE THE PART IF NECESSARY. SINCE THE WEAR LIMIT IS SPECIFIED AS A PERCENTAGE OF THE INITIAL DIMENSION IN SOME CASES IT IS ADVISABLE TO MAKE A TABLE INDICATING THE INITIAL DIMENSIONS AND THE WEAR CONDITION TO FACILITATE INSPECTION. 3. FASTENERS:LOOSE NUTS ETC. MAY RESULT IN SERIOUS TROUBLES. ON EVERY INSPECTON PAY SPECIAL ATTENTION TO TIGHTNESS OF ALL FASTENERS LIKE NUTS, LOCK PINS ETC. Page 10 of 11 M/s GRIP ENGINEERS PVT. LTD. Piyala Road, P.O.: Sikri, Ballabgarh 121102. Distt. Faridabad, Haryana (INDIA) Ph.:- 0129 4187400 Fax:- 0129 - 4187440 E-Mail :- fbd@gripengineers.com Web:- www.gripengineers.com
PERMISSSIBLE WEAR DO NOT USE THE PARTS OF THE CRANE OVER THE FOLLOWING LIMITS OF WEAR. THE PARTS WHICH ARE WORN OUT OVER THESE LIMITS SHOULD BE REPLACED IMMEDIAYELY. 1. 2. GEARS WHEELS FIRST PAIR OF GEARING OTHER GERAS FLANGES TREAD 10% OF TOOTH THICKNESS ON P.C.D. 20% OF TOOTH THICKNESS ON P.C.D. 50% OF FULL SIZE 30% OF FULL SIZE. WHEN THE DIFFERENCE IN DIAMETER BETWEEN RIGHT SIDE AND LEFT SIDES WHEELS EXCEED 1.5% REMACHINE TO RECTIFY. 3. 4. 5. 6. 7. SPROCKETS CHAIN HOOK BRAKE LINING WIRE ROPE PITCH OPENING THICKNESS NO. OF BREAKAGES SIZE AT HOOKING POINT 30% OF FULL SIZE 2% LONGER THAN ORIGINAL PITCH 5% MORE THAN ORIGINAL SIZE 20% OF THE ORIGINAL SIZE. 50% OF FULL SIZE 10% LENGTH 8. SHEAVES GROOVE DIA. 50% OF WIRE ROPE DIAMATER. OF TOTAL STRANDS PER EVERY STEEL OVER THE ENTIRE WIRES 300 mm LENGTH

1091-5 T Sgeot

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

1091-5 T Sgeot

Încărcat de

Drepturi de autor:

Formate disponibile

OPERATION & MAINTENANCE OF SINGLE GIRDER

OPERATING & MAINTENANCE INSTRUCTION

Job No.: Crane Serial No.:

GA DRAWING No.: ELEC. DRAWING No.:

INSTRUCTIONS FOR ERECTION OF CRANES

S-ar putea să vă placă și