LECTURE ON CRANE DESIGN

1. Classification :

Class A : (Stand by or Infrequent Service)

Installations like power house, public utilities, Turbine rooms, motor rooms,
Transformer stations etc. where precise handling of equipment at slow speed
with long, idle periods between lifts required capacity loads may be handle for
installation of equip and for infrequent maintenance.

Class B : (Light Service)

In repair shops, light assembly operations, service buildings, light warehousing

etc. where service requirements are light & speed is slow.

Class C : (Moderate Service)

Used in Machine shops, Paper mill machine etc. service required are
moderate handles loads which average 50% to with 5 to 10 lifts/hr,
average 15 ft.

Class D : (Heavy Service)

Heavy machine shops, foundries, fabricating plan steel ware houses, container
yards, lumber mill etc.

50% of rated load will be handled constantly 9 speeds, 10-15 /m.

Class E : (Severe Service)

Handles rated load through its lift

- Magnet, bucket, magnet/bucket combination scrap years, lumber mills,

fertilizer plants container handling. 20 or more lifts/hr.

Class F : (Continuous Severe Service)

Handling rated load continuously under severe service conditions throughout

its life. custom designed cranes essential to Perform the critical work tasks
affecting the total production facility.
- Structural Design

Structural Steel used should confirm to ASTM A36 Speci.

Welding design & procedures : AWS D141% specification for welding industrial
& mill cranes.
Dead load factor
Hoist load factors (Vertical Impact for)
= 0.15 < 0.005 (hoist speed) < 0.5

i.e. 0.5% of hoist speed (ft/min.) but > .15% rated

& < 50% rated

for bucket & magnet 50% of rated cap.

Skewing force = Sak x wheel load

Sak coefficient depends on Ratio = Span / wheel box

(given chart)

Deflection span / 888 = Camber remains same.

Wheel base span/7 or greater.

Wheel KW (mean effective load) = 2 (max.load) x min.load / 3

Mini load shall be established by the dead load of bridge & trolley only.

Ropes

(Cap + bottom b/k wt)

---------------------------- < breaking strength 0.2
no. of falls
i.e., fos = 5 mini
= 8 for moltan metal.

Sheaves :

Material : Steel or minimum ASTM grade A48, class 40 cast iron.

Or other suitable

Class 6 x 37 (rope)
A&B 16
C 18
D 20 Xd
E 24
F 30
Equaliser Sheave :

Eq. Dia > of sheave dia

& also not less than 12d for 6 x 37.

Drum :

Material CI-ASTM Grade A-48, Cl.40 equal.

Cast steel ASTM A27 or equal.

Mini Drum dia (PCD)

Class 6 x 37 (rope)
A&B 16
C 18
D 20 Xd
E 24
F 30

Gearing :

Hp rating of gears should be as per AGMA standard.

AGMA 221.02 Rating the strength of helical gears

211.02

Brake :

Hoist Service factor : 1.25 When used with control braking other than mechanical

1.0 When used with mech. control braking.

1.0 For each brake if 2 brakes used.

For molten metals : 2 brakes

Wheel : Should be designed on max. load rail : effective rail head width.

Max. load
D= ------------- = w is effective head width
WxK = k = BHN x 5 (for BHN < 261)
K = 300 (BHN/260)33 (for BHN>
CT Wheel :

(2 x y x cap / CT W.b.) + 1.5 Tro wt.

CT load factor ktw = ------------------------------------------------
(3 x y x cap / CT W.b.) + 1.5 Tro wt.

LT Load factor
0.75 (bridge wt) + (span HA) / span (cap + Tr.wt)
+ 0.5 (tro.wt 0.5 (SP-HA)(/s x tro
Kbw = -------------------------------------------------------------------
0.75 (bridge wt) + 1.5 x (span HA)IS fan v(cap + tr. wt)

Hoist Motor

Wxv
Mech. Hp = -------------
33000 x E

w = cap + bottom blk wt. (in Pound)

v = Speed ft/min.
E = Eg.n + Esm rope syst. Eff (0.99)m

Per stage eff. Of gear (0.97)

Rated Hp = Mech. Hp x KC.

KC = control factor
= 1 for AC wound motor.

CT & LT Motor :

Hp = Ka x w x v x ks
Ka = acc factor for type of motor.
Ks = service factors which accounts for the type of drive and duty cycle.
W = total weight to be moved including all dead & live loads in Ton.
V = speed in ft/min.

F x 2000a x Cr
--------------------
GxE Nr.
Ka = --------------- x ----
33000 x KE Nf.

F= rolling friction of drive (including transmission losses) in pounds per ton.

(depends on wheel dia)
a= average or equivalent uniform acceleration rate in feet per section.
Cr = rotational inerdia factor.

Wk2 crane & load + Wk2 of rotating mass

------------------------------------------------------- 1 lbs = 0.454 kg
wk2 of crane & load 1 ft = 3.33 m

OR

1.05 + (a/7.5) if wk2 is not known.

G = 32.2 feet per sec2

E = Mech. Efficiency
Nr = rated speed of motor in rpm
Nt = free minning rpm of motor when driving at speed v.
Kt = equi. Steady state torque relative to rated motor tg.
2. Seismic Calculation as per IAEA Tecdoc 348

The story lateral load Fi.

Fi = ag.Ci.Wi

Where, ag = dsn accln applicable at the ground surface level & defined by
Ag = Y ab
Y = 1 for soil calegorization.
Ab = 0.08 for Design intesity level.

Ag = 0.08 0.1

Ci = CDi = coefficient related to the building characteristics and defined as

(D1.D2.D3)
CDi = ---------------
d

D1 = standard response factor depends on fundamental period of str. (T b)

Tb = HB(DB)-1/2

HB
= ------
DB

= 0.37

D1 = 2 for Tb = 0.37

D2 = coefficient related to damping to be dd min ed from D.

D2 =1

D3 = 1 + 0.5 (hx/Hb)

Hx = ht. of point with respective to G.L.

Hb = ht. of building.
Assumed hx/Hb = 1

D3 = 1.5

= (2-1)

= 2.2 for reinforced concrete.

 d = 1.84
(D1.D2.D3)
Hence, Cdi = Ci = ---------------
d

(2x1x1.5)
= -------------
1.84

Ci = 1.63

Dynamic Approach (CDi)

Fi = 0.1x1.63
Hence ---
Wi = 0.163 floor acceleration..(1)

Equipment Design :

Equipment design, dynamic approach is reg. Seismic coefficient CD; is used to

evaluated the horizontal and vertical Seismic loads or equipment, FEH, FCV
at ht. hx.

FEh = CD1 x D4 x We

Fev = 0.5 FEH

We = weight of equipment.

D4 = amplification factor due to floor response spectrum.

Af = (b + e)2 + mr -

Bb = Bbb Be = Be x e for Tb > 0.5

Bb = damping for building = 0.05

Be = damping for equipment = 0.05
Mr = Mass ratio Me/Mb = 0.01 (assumed)
Me = Mass of equipment.
Mb = Mass of building
b = ductility coefficient = (2-1)