IWAI
11
MOBILE HARBOUR CRANE
11.1
OPERATING CONDITIONS
Mobile Harbour Crane shall be of rubber-tyred, self-contained construction and shall be equipped with a diesel engine as a prime mover for crane operation and travelling. The crane shall be of four-rope construction and shall be designed and equipped for multi-purpose operation like general cargo handling, bagged cargos, heavy lift operation as well as containers with automatic Spreader and bulk handling with suitable four rope grab. Crane will cater to barge up to 3000 DWT size with the dimension of 95 x 15 x 2.5. Being a new terminal and to have edge in the industry market, equipment should have maximum efficiency to perform highest in its c lass. 11.2
MAIN TECHNICAL REQUIREMENTS
The following minimum operating characteristics are required: 11.2.1
Load Capacities
11.2.1.1 General Cargo Handling The crane shall have a lifting capacity of minimum 40T on hook up to a radius of 20 m from crane centerline. 11.2.1.2 Four Rope Grab Operation The crane shall have a lifting capacity of minimum 20T in grab mode up to a radius of 20 m from crane centerline. 11.2.1.3 For Container Handling The crane shall have a lifting capacity of minimum 30T under spreader up to a radius of 20 m from crane centerline. Spreader weight is about 7.6 t. Total weight of the loaded container considered as 30 T. 11.2.2
Classification Classification of Crane and Machinery
The crane and its machinery shall be classified according to the FEM 1.001 (Rules for the Design of Hoisting Appliances) and shall have the following minimum classifications: 11.2.2.1 Crane Classification Heavy lift operation 50 T on hook
– A4
Grab Operation
– A8
Container Operation
– A7
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11.2.3
Operating Speeds
The following speeds shall be provided as a minimum:
11.2.4
11.2.5
11.2.6
Hoisting/ Lowering
0-50 m/min
Slewing
0-1.2 rpm
Luffing
0-40 m/min
Travelling
0-60 m/min
Main Dimensions:
Minimum outreach of the boom from crane centerline
20 m
Height of boom pivot point above ground
minimum 8 m
Height of eye level in tower cab
minimum 13 m
Maximum hoisting height on hook above ground
minimum 33.5 m
Minimum hoisting height on hook below ground
10 m
Quay Load Arrangements
Uniformly distributed load under pad
1.5 T/m2
Max. Load per tyre
5T
Environmental Conditions
The crane shall be designed to work safely and reliably under the following environmental conditions: 0
Temperature range
±25 C
Maximum operating wind speed
24 m/s
Maximum wind speed for travelling
24 m/s
Maximum wind speed out of operation with boom in steepest position
46 m/s
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11.2.7
Detail Technical Requirements
11.2.7.1 Chassis The chassis of the crane shall be constr ucted as a welded steel structure in a stiff box design to carry the forces and moments occurring in crane and travel operation. The steel structure of the chassis shall be fitted with two head beams for accommodation of the stabiliser beams, which are extended and retracted by means of hydraulic cylinders inside the head beams. By means of hydraulic cylinders the stabiliser pads shall be lowered, to prop the crane, and raised. The stabilisers should be operated in automatic or manual modes. Access from quay to chassis shall be provided by stairways at the end of the chassis. The superstructure shall be accessible from the chassis in every position of the superstructure to allow safe exit in case of an emergency. The stabiliser pads shall be pivotably mounted on the jack cylinders and shall be easily removable. The filler neck for filling the fuel tank shall be located at the chassis at ground level in order to enable refilling of the fuel tank during crane operation. The axles and axle suspensions shall be of robust low-maintenance mechanical design and shall be equipped with tyres of large diameter in order to allow safe travelling also in case of uneven ground. The axle suspension system shall compensate height differences of ± 250 mm in order to cross obstacles (> 100 mm) such as rails and dips without difficulty. The number of individual components of the travelling gear and the suspension system shall be kept to a minimum in order to avoid frequent failures of components. The steering system shall allow conventional travelling and steering motions as well as crab steering to facilitate slight sideward movements of the crane. All steering manoeuvres shall be safe also at maximum permissible wind speed. The chassis shall be equipped with a weather proof cab at the front side near ground level, equipped with a detachable control panel which can be used wirelessly as well. The chassis cab shall be equipped as a minimum with an adjustable driver seat, safety glass, a heater system, a ventilation system, wiper and washer system. In the steel structure of the chassis four fixed lifting points for lifting the fully mounted crane shall be incorporated in order to allow transport of t he crane in fully rigged condition. 11.2.7.2 Superstructure The superstructure shall be a stiff welded steel load-bearing structure designed to carry all the forces and moments occurring in crane operation. The superstructure shall accommodate the diesel-generator system, the hoist, the slewing gear, the pressure oil unit as well as a fully enclosed electrics room. VOLUME –II: Technical Specification and Drawings for Construction of Multimodal IWT Terminal at Haldia, West Bengal
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The access route to the tower cab shall be via walkways and stairways at the outside of the machinery house in order to keep crane operators out of the machinery room due to safety considerations. 11.2.7.3 Main Drive System The crane shall have a diesel-electric drive system in order to provide maximum efficiency and lowest operating costs. An adequately dimensioned diesel generator set shall be located in a separate room of the superstructure. The diesel engine shall be running at constant speed and shall be connected to a three-phase generator. Diesel engine and generator shall be installed in a common containerized room in order to facilitate exchange of the entire set in case of a failure. The crane shall be prepared for running on electrical shore power supply as well. An electrical cabinet at the chassis shall be provided with terminals to feed the crane for full crane operation from a shore power supply in case of a diesel engine failure. This also shall act as a preparation for retrofitting a full electrical shore power supply (incl. cable reel and trailing cable) in the future without the need of further internal installations (cabling, slip ring, motors etc.). In case of full electric operation regenerated energy shall be fed back to the shore grid when braking or lowering the load to minimize energy consumption. 11.2.7.4 Hoist The crane shall be equipped with a hoist system comprising one rope drum, one completely enclosed spur gear reduction unit, spring-loaded disc brake and an electric motor. The hoist ropes shall be coiled in one layer on the milled rope drum in order to keep the wear low. A nearly horizontal load path during luffing is required. The number of individual components of the hoisting gear shall be kept to a minimum in order to avoid frequent failures of components. 11.2.7.5 Slewing Gear The superstructure shall be 360 degrees rotatable. The slewing gear shall consist of an electric motor, a disc brake, a three-row roller bearing slew ring with internal toothing and a fully enclosed planetary reduction gear unit. 11.2.7.6 Luffing Gear The boom shall be luffed in and out by means of a hydraulic luffing cylinder that holds the boom in position. The luffing cylinder shall be mounted below the boom in order to avoid the boom falling down in case of a rupture. The valve block shall be located directly at the bottom of the cylinder and shall be equipped with safety valves which hold the oil pressure inside the cylinder even in case of hose damage. The valve block shall be accessible from a platform without the need of using personal protective equipment. VOLUME –II: Technical Specification and Drawings for Construction of Multimodal IWT Terminal at Haldia, West Bengal
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11.2.7.7 Tower The crane shall have a tower with a high boom pivot point, a suspension for the tower cab, support for the rope pulleys as well as means of access to the tower cab inside the tower construction. This access shall be designed in a spacious way having a stair angle of maximum 50 degree from horizontal. Spiral staircases shall be avoided to facilitate access. Sufficient maintenance platforms for boom pivot point and for the rope pulleys are to be provided. 11.2.7.8 Boom The boom shall be of a welded tubular-lattice design having three chords. The connecting chords and cross-members of the boom shall be welded by special castings in order to improve the notch effect and to decrease the possibility of cracking. A motorized cable reel at the boom head shall be provided to coil and uncoil the electrical cable for hook rotator, automatic spreaders, electro-hydraulic grabs, magnetic lifting devices etc. 11.2.7.9 Tower Cab The crane operator shall be able to operate and control all functions of the crane from a spacious, ergonomically designed tower cab having large windows and a cab position high on the tower. The tower cab shall be made of steel plates and sections which are protected against corrosion in a salt-laden, marine environment by a tried-and-tested paint finish. The cab shall be fitted with safety glass windows. The non-glazed surfaces shall be panelled with a heat and sound insulating material having a dark colour scheme to minimise reflections from the windscreen. As a minimum the cab shall have the following features: adjustable upholstered operator seat, a front window with variable opening, all controls and indicators for crane operation and travelling, air outlets, air conditioner, electric heaters, wiper and washer system, lighting, communication system, CD radio. The crane shall be equipped with a crane management system, displaying all the crane functions in an easy-to-understand form on a colour screen near the crane operator seat. The majority of the functions shall be selected with function keys on the screen, minimizing the number of individual hardware function keys next to the operator’s seat.
11.2.7.10 Hook Rotator A motorized electro-hydraulic hook rotator with ramshorn hook shall be provided.
VOLUME –II: Technical Specification and Drawings for Construction of Multimodal IWT Terminal at Haldia, West Bengal
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11.2.7.11 Lubrication System An automated motorized lubrication system for boom pivot point, luffing cylinder pivot points, slew bearing and slew pinion shall be installed. 11.2.7.12 Safety Equipment The crane shall provide the following safety equipment as a m inimum:
Safe load indicator
Mechanical interlock of chassis and superstructure during travelling
Stabiliser monitoring
State-of-the-art electronic limit switching system
Safety valves at hydraulic cylinders
Anemometer
Emergency stop buttons at various locations of the crane
Video camera at the boom tip
Appropriate lighting system for night-time operation
Crane management system (optional)
11.2.7.13 Electrics Room A totally enclosed and lockable electrics room shall be provided for accommodation of the crane control system as well as the electric control equipment. The electrics room shall be completely separated from the machinery room(s) and shall have a se parate entrance door. The electrics room shall be dust-proof. Sufficient split-type air conditioners and heating measures shall be provided.
11.2.7.14 Electrical Control System / Central Control Computer All crane functions shall be controlled and monitored by a programmable logic controller (PLC). The PLC hardware and software system shall be of an international well-known brand, preferably Siemens, to facilitate maintenance and troubleshooting by local engineers without the need of prior extensive special training on the manufacturer’s own system.
As an option the bidder shall include a web based remote monitoring system displaying main crane operation figures, crane maintenance issues and crane faults in real-time via a 3G mobile network connection. The monitoring capability shall be accessible via any web-linked computer via a standard web browser client. The crane must not have any proprietary electric or electronic control components that prevent the port from acquiring parts or services from local or third parties. Electronic control VOLUME –II: Technical Specification and Drawings for Construction of Multimodal IWT Terminal at Haldia, West Bengal
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components of the crane shall be available from third parties within India and not only through the crane manufacturer. In addition, purchase should have an option to source the parts locally through respective OEMs.
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