45-Ton Port Handling Crane at Song Lam International Port

Safe lifting capacity at all reaches: 45 tons at 26.5m reach

Safe lifting capacity at all reaches: 40 tons at 29.5m reach

Lifting capacity under grab: 35 tons at 29.5m reach

Reach (calculated from the crane center)

Maximum reach with hook: 29.5m
Minimum operating reach: 3.5 m

Time to change reach from Rmax – Rmin: 73 seconds

Operating speed:

Speed of lifting/lowering full load 45T with hook: 0 ÷ 15 m/min.
Speed of lifting/lowering full load 40T with hook: 0 ÷ 17 m/min.
Speed of lifting/lowering full load 30T with hook: 0 ÷ 22 m/min.
No-load lifting/lowering speed: 0 ÷ 33 m/min.

Description

VINALIFT provided 2 sets of 45-ton Port Handling Crane – port cranes for Song Lam International General Port, contributing a part to help the project be completed on schedule.

Song Lam Nghe An International General Port project is implemented by the investor Song Lam Cement Joint Stock Company (part of The Vissai Cement Group) in coordination with consulting units and contractors. When the project comes into operation, it will attract demand for general goods storage, packaging, packaging, warehousing, and rotation of goods through seaports. As expected, this deep-sea port area will create a driving force for development in the North Central region and promote economic exchanges with the Northeast regions of Thailand and the Central region of Laos. With those needs, a quality port handling crane with flexible reach is a device not to be missed.

GENERAL INTRODUCTION

pedestal crane installation — Pedestal crane installation

WHAT IS A PORT HANDLING CRANE?

Pedestal crane or Port Handling Crane is a type of crane that specializes in loading and unloading goods at ports, factories, and yards running on rails. The advantage over other types of gantry cranes is that they are flexible in their intended use and are a perfect combination with general ports with a variety of goods to be loaded and unloaded.

Design conditions

Environmental working temperature: -25°C ÷ 45°C

Maximum humidity: 96 %

Calculated wind speed when the crane is working: 20 m/sec

Wind speed when not working: 36 m/s

Design standards

F.E.M 1.001 October 1, 1987, QCVN 22:2010/BGTVT (National technical regulations on manufacturing and inspection of vehicles and loading and unloading equipment of the Ministry of Transport): Rules for design of lifting equipment

Working mode

Group classification according to F.E.M 1.001 standard (latest version), QCVN 22:2010/BGTVT (National technical regulation on manufacturing and inspection of vehicles and loading and unloading equipment of the Ministry of Transport) is as follows :

Entire crane	Level of use	U5
	Load level	Q2
	Hierarchical group	A5

Stability

The stability of the crane is designed in accordance with F.E.M 1.001 standards (latest version), QCVN 22:2010/BGTVT (National technical regulations on manufacturing and inspection of loading and unloading vehicles and equipment of the Ministry of Transport). Transportation).

Main information

Safe lifting capacity at all reaches: 45 tons at 26.5m reach

Safe lifting capacity at all reaches: 40 tons at 29.5m reach

Lifting capacity under grab: 35 tons at 29.5m reach

Reach (calculated from crane center)

Maximum reach with hook: 29.5m
Minimum operating reach: 3.5 m
Time to change reach from Rmax – Rmin: 73 seconds

Operating speed:

Speed of lifting/lowering full load 45T with hook: 0 ÷ 15 m/min.
Speed of lifting/lowering full load 40T with hook: 0 ÷ 17 m/min.
Speed of lifting/lowering full load 30T with hook: 0 ÷ 22 m/min.
No-load lifting/lowering speed: 0 ÷ 33 m/min.

Revolving speed: 0 ÷ 1.2 rpm

Base movement speed: 0 ÷ 18 m/min

Rail aperture: 14.6 m

Clearance height below base: 12 m

Travel length: 150m

Center distance between two sets of legs along the moving rail: 14 m

Base height from rail top to slewing bearing: 21 m

Total number of wheels: 28 pieces

Wheel diameter: 500 mm

Maximum pressure on the wheel: 30 tons

Lifting motor power: 250 kW

Moving mechanism actuator:

Motor power: 5.5 kw x 8 sets
Power source: AC 3 phase, 380V, 50Hz
Sealing level: IP55
Manufacturer: BONFIGLIOLI

Power supply: 380V, 3 phase, 50Hz

Mining productivity: 18~22 times/hour

Rail type: A100

Maximum noise level of the entire base when operating: < 85dB (within 6m from the noise source)

Crane certification: Safety inspection center.

TT	List of goods	Specifications
1	Design and design approval.	Applied standard: FEM 1.001 TCVN 4244-2005
2	TTC 230 ELS lifting rod
3	Fabrication of steel structure base frame including Main beam, foot beam, stairs, railing, working floor, and counterweight concrete.	Material SS400/Q235B/Q345B/Q355B
4	Electrical control system for cranes moving along the rails (equipment including inverter, PLC, and other auxiliary equipment).	55Kw inverter
5	The cable reel assembly is used to supply power to the crane operating along the railway track. 560 KVA-KP Korea dry transformer synchronized with the substation shell.	Code: TKC300 Medium voltage 6KV Medium voltage power cable 335mm2+325/3, operating range: ± 150 meters
6	Gear reduction motor for crane movement.	Power 5.5 kW
7	Rail end damping system.	Made of rubber
8	Rail clamping system.	Mechanical type
9	Hệ thống đảm bảo an toàn khi gió bão.	The system ensures safety during storms.
10	Scroll wheel.	Surface hardness: 38~42HRC Material: S45C Diameter: 500mm
11	Safety devices.	Rotating lights, moving siren
12	Lighting system, fire prevention.

STEEL STRUCTURE

General introduction

The structure consists of box beams welded together to ensure rigidity, stability, and ease of inspection and maintenance. The base is made from steel with a yield limit of ≥235 N/mm2, a durability limit of about 373-480 N/mm2, and a relative elongation of 24% or equivalent.

Welding rods used for structural welding are welding wires according to AWS standards. The welding wire is dried in a temperature oven according to the welding process approved by the registry. The material cutting edge will be cleaned by the grinding method. Before tack welding, the structural steel welding step is only carried out after joint inspection has been completed and only by certified welders and according to approved procedures.

The steel structure consists of 3 parts: The main beam, support leg, and foot beam described as follows:

Main girder

The main beam is designed in a box shape to ensure rigidity, and good bending and torsion resistance, and is lightweight. Above the beam on the riverside, a cylindrical tube is welded with a thickness and diameter corresponding to the adapter tube of the portal handling crane. This connecting pipe goes into the main beam connecting the upper and lower panels of the beam. The bottom of the beam is connected to the legs with a welded connection.

Welding the base with the crane connecting tube ensures concentricity and fracture of the centerline of the crane cylinder.

Support structure

The support legs are box-shaped and triangular, ensuring rigidity, compactness, and aesthetics. The support leg includes the shore leg and the water leg. The support structure is installed with the main beam. The main beam and support legs are designed with manholes to allow workers to get inside for structural inspection and maintenance.

Footsteps

Box structure. The leg beam is welded to the leg structure with ears assembled with the moving mechanism.

Depending on the load-bearing area of the main beam, legs, and auxiliary beams, different corrugated iron thicknesses, and structural cross-sections are allowed so that a reasonable structure ensures optimal durability and the most stable crane operation.

Stairs, railings

The stairs run along the foot of the shore, wide enough to reach the main girder, into the crane shaft and up to the crane cabin. You can also go inside the base to check and preserve equipment and steel structures. The stairs have sturdy handrails. The top of the main beam has a safety railing installed. The pipes used for railings and handrails are steel pipes. Working floors, walkways, stairs, ladders and guard rails are hot-dip galvanized according to QCVN or equivalent.

CƠ CẤU DI CHUYỂN CẦN TRỤC CHÂN ĐẾ

port handling crane at Song Lam International Port — The port handles crane at Song Lam International Port

General introduction

The steel structure is supported by a system of wheels that can move on rails. The entire crane is supported on wheels, installed in a system of multi-level balance beams to ensure that the crane’s load is evenly distributed across all wheels. The electric motor provides proper wheel drive for good operation in wind conditions of 20 m/s.

Transmission

Motor-type transmission attached to the gear reduction box, three-phase electric motor with high and stable starting torque attached to the sealed gear reducer, lubricated by oil, ensuring high transmission efficiency

Each motor is equipped with an electromagnetic brake. This brake system will automatically apply when the power source is lost, ensuring safety when the crane stops operating. The brake system will release automatically when power is restored.

Open gear transmission

Pairs of spur gears are installed to transmit motion from the motor transmission to the active gears. The whole thing is placed in an active wheel box to ensure safety.

Wheels, axles, and bearings

The wheel is designed for A100 rails. The wheels are made of S45C cast steel and the working surface is hardened to 38~42HRC.

Shafts are made of S45C steel or equivalent.

Use anti-friction bearings with lubricating grease. Wheels, axles, and bearings each have the same assembly size so they can be replaced and mixed easily. Bearings: TIMKEN, FAG, ZKL or equivalent.

Lifting jacking points

To facilitate the repair of wheel assemblies and relocation of the crane. Below the main balance beams, jack bearings are machined and installed.

Damping heads

There are 4 rubber damping stops installed at the four corners of the crane, which will correspond to the stops, installed on the end of the dock’s rails. The dampers must be able to stop the crane, avoiding damage, when the crane is fully loaded and moves to the end of the rail (using a limit switch).

Clamping mechanism

The rail clamping mechanism is installed on top of the wheel box on both sides of the rail. This mechanism locks the clamp with the rail, when the crane stops operating, ensuring the crane does not move.

Storm-resistant structure

The two anti-storm assemblies are manually operated according to the principle of lowering the latch to ensure safety and ease of operation to anchor the crane in a fixed position (including the latch hole at the wharf). These assemblies have the ability to hold the crane in stormy wind conditions.

Control and safety structure

The movement of the crane will also be controlled from the cab and from the railing of the base girder frame by means of arms or control buttons. The control arms will return to a neutral position when there is no driver action.

Two limit switches at the upstream and downstream rail ends of the terminal ensure that all crane motors are de-energized, to avoid damage.

Two emergency stop buttons located at the support base will turn off power to the entire crane when activated, causing an emergency stop in necessary cases.

When the crane moves along the rail, warning lights (flashing lights) will flash at each corner of the moving mechanism and the warning horn will operate.

Maintenance, lubrication

Let the wheel system work well and safely. The wheel system is designed reasonably and conveniently for regular lubrication and ensures the moving mechanisms work in a lubricated environment.

The bearings of the moving wheels and the shafts and open gears are periodically lubricated with general-purpose grease. Grease will be pumped through copper grease nipples

M10x1 installed right at the shaft ends. The gear reducers are lubricated with oil, the type of oil and the capacity of the oil tank are specified by the manufacturer HGT. In the beginning, lubricating oil was pre-filled by the manufacturer in the HGTs.

Lubricated positions on the moving foot assembly:

TT	Name	Oil type, lubricating grease	Lubrication mode
1	Speed Reduce Box	Oil (according to the gearbox catalog)	As specified by the Manufacturer
2	Open gear pair	lubricant grease	Regularly every 6 months
3	ball bearings at the wheel	lubricant grease	Regularly every 6 months
4	Dynamic joints at balance beams	lubricant grease	Regularly every 12 months

Counterweight for base

The counterweight for the crane base is calculated and designed properly to ensure stability and rigidity for the crane in all cases.

WELD

General requirements

Chamfering specifications, quality of assembly of details, and weld sizes satisfy standard welding or drawing requirements.
T-shaped welds can withstand dynamic loads, ensuring the weld penetrates the entire thickness of the base metal. T welds are continuously welded on both sides. The T-weld face has a concave shape and gradually transitions to the base metal face. There are no cutouts at the edge of the weld.
The welds at the transition sections and in the tip area have no grooves and have a constant cross-section and shape.
The weld is free of air porosity and slag. The base metal along the weld edge must not have grooves deeper than 0.5 mm.
Butt welds have full penetration throughout the entire thickness of the joined elements. When joining two plates of different thicknesses, the edge of the thick plate is beveled to equal the thickness of the thin plate.

Prepare the weld edge

Assembly: Do not use forced measures and do not cause stress in the structure when assembling the structure for welding. Welded joints meet quality requirements according to regulations.

Weld:

Welding wire for tack welding is the same type as the official welding wire according to AWS standards.
Immediately before welding, the edges of the base material are cleaned of grease, rust, paint, etc.
When welding multiple layers, clean off the slag on the previous layer before welding the next layer.

ELECTRICAL PARTS

The power supply for crane operation is 3-phase power, 380V, 50Hz. Electrical systems such as installing electrical cabinets to supply power to the entire crane. Install equipment for crane moving clusters and moving safety devices. Providing good quality electrical equipment for cranes, specialized for lifting equipment.

Cable drum with a total crane travel length of 300m, power supply point in the middle of the runway.

Standard

Electrical equipment installed on the crane must be manufactured according to Vietnamese standards/or IEC international standards.

Electrical cabinets and distribution cabinets

The electrical cabinet is made from thick sheet steel, fitted with a lifting hinge at the front of the door to allow the replacement of electrical equipment without having to remove the insulation panel.

When manufacturing the electrical cabinet shell, it is washed and cleaned of grease, phosphate treatment, and electrostatic painting. All electrical units and panels are in a covered position to allow inspection or maintenance in all weather conditions.

The distribution cabinets are placed so that it is convenient to connect wires to the electrical cabinet.

All lighting and drying heat must be provided through a separate distribution cabinet with separate circuit breakers.

Conductors on electrical cabinets and distribution cabinets are insulated with PVC material.

Approved signage names for the front of cabinets and entrances indicate the purpose of the equipment.

The enclosed electrical cabinet is sized so that the equipment is maintained normally or in operation, and must not be mounted higher than 1,300mm above the foundation level.

Main circuit breaker 380/415 V

Provided by: Mitsubishi, Schneider

Contactor

AC contactors operate under heavy-duty type AC-3 and type AC-4 with AC operating coils and comply with the appropriate standards.

DC contactors are heavy-duty or equivalent and are fitted with removable terminal switches, trip arcs and magnet blocks.

Relay

The control relay has a heat rating of no more than 10amps.

Overload – short circuit protection

The thermal overload relay for AC motor is 3-pole type with single-phase protection.

Electrical equipment

All motors are waterproof with all-weather protection and fans, and grease pumps and those without covers are protected from sunlight. The motor is fully adapted to the seawater environment to withstand sea air and withstand salt and dirt.

Electrical equipment and motors must have appropriate rated capacity with protection against overload.

The AC motor can start from any load to full load when the supply voltage is 85% of normal voltage.

Every motor operates vibration-free and with minimal noise. The motor needs to be statically and dynamically balanced.

The motor bearings all have easy-to-grease places to prevent the bearings from getting stuck.

The moving motor’s speed is adjusted by an inverter.

The controlling system

PLC is an independent intelligent system capable of performing calculations, capable of connecting to a variable-velocity dynamic system, a system capable of providing predicted parameters in memory. PLC.

The alarm and trouble diagnosis system will coordinate error messages and system status as soon as an error occurs.

PLC has an automatic control system, checks and can indicate errors, and has memory to store data in case of power failure.

Limit and protection switches

Limits and protective switches are mounted to limit all activities of the structures, preventing damage in case of exceeding the travel in all directions, for example, limiting the moving mechanism at both ends of the rail.

Submit electrical drawings

All details of electrical drawings are submitted to the customer before fabrication.

Accessories for low-voltage

The device uses 220 volts

It is planned to provide three-phase 380/415-volt 60-ampere wiring with sockets in the engine room, 2 such sockets in the driver’s cabin, and under the moving frame.

There are two 220-volt plugs for general use in the cab or driver’s compartment, and two such outlets in the electrical/hydraulic cabin.

Light

The working area under the crane and on the bridge is illuminated by high-pressure lights with capacitors to improve the power factor with reflectors to prevent the driver from being dazzled. From the cabin, the driver can operate easily.

The passage from the berth to the engine room in the cabin is lit by several suitable lights, controlled by many switches such as:

Lights on structures must be collected for work in groups

From the point near the entrance to the stairs, on the ground.
From a point in the engine room near the entrance.
From a point from the stairway to the driver’s cabin.
From a point in the driver’s cabin.

Lighting mounted below the level of the top of the rail shall be provided to illuminate floors, walkways, stairs and ladders.

Watertight, vibration-proof fluorescent lamps are used in the room.

The lamp is mounted so that vibration does not affect the lamp mounting point.

The installation of components ensures protection against corrosion due to hydro and electrical effects

The control and control unit for the headlights is located near the lighting distribution cabinet, or in the engine room for easy operation and maintenance.

The lamp mounting is designed to withstand vibrations caused by crane movements to maximize the life of the lamp. The method of mounting the lights in a reasonable position makes it easy to replace spare parts from the stairway entrance.

Wind gauge

The crane is equipped with this clock, which gives instructions to the driver and has an alarm on one leg of the crane at ground level. The transmitter must be mounted on the highest point of the crane’s permanent structure.

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