Amptpl: Adani Murmugao Port Terminal Private Limited

ADANI MURMUGAO PORT TERMINAL
PRIVATE LIMITED AMPTPL
CLIENT MORMUGAO PORT TRUST
PROJECT DEVELOPMENT OF COAL TERMINAL AT BERTH NO. 7, PORT OF

MORMUGAO, GOA, INDIA
TITLE DESIGN BASIS – SHIP UNLOADER (MOBILE HARBOUR CRANE RAIL

MOUNTED)
DOCUMENT NO. AMPTPL/E118.001/M011/DB01 Rev. 0
NOTES
REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

NO. BY SIGN BY SIGN BY SIGN
0 22.06.10 Design basis – Ship Unloader TR JB VKS
This Document is the property of AMPTPL. It should not be used, copied or reproduced without their written permission.
Design Basis Report - Ship
Unloader
Coal Terminal Development at Mormugao
Port, Goa
R-0
AMPTPL
June 2010
1 BASIC DETAIL & MATERIAL CHARACHERISTICS
1.1 BASIC DETAILS
i. Avg. throughput required: 45000 MT/Day
ii. No of crane: 2nos.
iii. Type of crane: Rail mounted mobile harbour crane
iv. Model: To be decided with supplier
v. Deck top level: +4.8
vi. Tidal details: Given below
vii. Hopper height: 14.6 mtr from the top of berth
viii. Ship size: Max 100,000 DWT, Min 20,000 DWT, Avg. 60,000 DWT
ix. Other Details : Similar to Dahej Site
x. Power Supply: 6.6 KV
1.2 MATERIAL CHARACTERISTICS
The coal terminal will be designed for thermal and cooking coal, for use in
multiple user facilities including bulk use in power plants.

Table 1‐1 Material Specifications
Material Coal
Density 800
Angle of repose 37°
Moisture Content% Up to 40%
Max Lump size 100 (upto 150) mm
Abrasive mildly
2 SITE CONDITION AND PHYSICAL SETTINGS
2.1 SITE LOCATION
The port of Mormugao, one of the oldest ports of India commissioned in 1888
and one among the 13 major ports in India, is situated in Goa state, between the
major ports of Mumbai and New Mangolore. It is located at the mouth of river
Zuari at latitude 15° 25’ North and longitude 73° 48’ East & Goa is located at a
distance of about 580 km south of Mumbai. The current project area is situated
on the right side of South West Port Limited coal handling terminal.
2.2 TOPOGRAPHIC FEATURES
There is neither significant vegetation nor any habitation in the proposed Port
area. The existing level in the back up area is in the range of + 4.0 m CD to + 5.0 m
CD. Area immediate behind the proposed berth is having levels in the range of –
3.0 m to – 11.0 m CD. Port back up area will be filled with suitable reclaiming
material. Area gently slopes towards sea coast.
2.3 BATHYMETRY
Information regarding Bathymetry in the region is available on Sea Charts 2020
& 2078. The area has also been surveyed by MPT Goa Survey Department by
taking dense soundings. The survey charts developed by Survey department
MPT Goa are attached in Annexure C.
2.4 METEOROLOGICAL AND OCEANOGRAPHIC CONDITIONS
The Met‐Ocean conditions have been previously ascertained at several stages in
the course of various studies conducted in past in respect of MPT Goa Port
Development. The site of the Proposed Port is in the same region. Flow modeling
for the proposed location has been covered in the Model developed by CWPRS
Pune, who has developed the model Port area.
The climate of the region is tropical, characterized by two monsoon seasons viz.
the south west monsoon (mid June‐September) and the north east monsoon
(December‐March). The post monsoon period comprises the months of October
and November while the period April to mid June is the transition period.
Main conditions having significant bearing on Planning and Design of the Port
are described here in below.
2.4.1 RAINFALL
Table 2 shows the average rainfall for different months of the year and the
number of rainy days in each month. Rainy day is a day with at least 2.5 mm
rainfall.

Table 2‐1 Average Monthly Rainfall
Month Average Number of Rainy
Rainfall (mm) Days
January 0.2 0.0
February 0.1 0.0
March 1.2 0.1
April 11.8 0.8
May 112.7 4.2
June 868.2 21.9
July 994.8 27.2
August 518.7 23.3
September 251.9 13.5
October 124.8 6.2
November 30.9 2.5
December 16.7 0.4
Total 2932 100.1
Source: IMD
90% of the total annual rainfall occurs during the months from June to
September. There are, approximate 100 rainy days per year.
2.4.2 TEMPERATURE
The monthly average air temperatures are as shown in Table 1.
Table 2‐2 Average Monthly Air Temperatures
Month Average Maximum (ºC) Average Minimum (ºC)
January 31.6 19.6
February 31.5 20.5
March 32.0 23.2

Month Average Maximum (ºC) Average Minimum (ºC)
April 33.0 25.6
May 33.0 26.3
June 30.3 24.7
July 28.9 24.1
August 28.8 24.0
September 20.5 23.8
October 31.6 23.8
November 32.8 22.3
December 32.4 20.6
Source: IMD
From the averages, it is observed that April and May are the hottest months of
the year with the highest average maximum and the highest average minimum
temperatures while January and February are the coldest months of the year
with the lowest average maximum and lowest average minimum temperatures.
The highest temperature recorded was 39ºC on 12 March 1979 while the lowest
recorded was 13.3ºC on 25 February 1965.
2.4.3 PREVAILING WIND AND CYCLONES
The normal wind force varies from 4 to 7 on the Beaufort Scale. The direction is
mainly from South‐West, West and North‐West during the monsoon season.
During the rest of the year wind direction is from North, North‐East, East and
South‐East in the morning and from South‐West, West and North‐West during
the evening. The highest average wind speed is in the range of 30 kmph,
recorded in July 1965. The highest speed is 80 kmph, recorded in July 1965. The
highest speed is 80 kmph, recorded in December 1966. The wind forces more
than 10 on the Beaufort Scale are not expected.
Mormugao is not situated in a pronounced cyclone zone and the number of
occasions it was visited by cyclones during the past 90 years is less than a dozen.
For the design of the Berth, an operating wind speed of 26 m/sec and the storm
basic wind speed of 39 m /sec shall be considered as per IS:875‐Part 3.
2.4.4 WIND CONDTIONS
The mean wind speed varies from 2 on the Beaufort scale in November to 4 in
July, the annual mean wind speed being 13.6 KMPH. In an average year, there
are 316 days with wind varying from 0 to 3 on the Beaufort scale and 48 days
with winds scaling 4 to 7 on the Beaufort scale, and 1 calm day.
The predominant wind direction changes with the time of the year. During the
period June – September wind blows from the W and SW. During the remaining
period, the wind direction is from NE, ESE.
2.4.5 TIDES
The nature of tides prevailing at Mormugao is mainly semi‐diuranl exhibiting
two high and two low waters in a tidal day. The mean tidal variation is of the
order of 1.6 m at spring tides and around 0.7 m at neap tides.
Based on Indian Naval Hydrographic Chart No. 2020, the tide levels with respect
to chart Datum at Mormugao harbour are as follows:
Higher High Water at Spring Solstices ‐ +2.3 m
Mean Higher High Water (MHHW) ‐ +1.9 m
Mean Lower High Water (MLHW) ‐ +1.8 m
Mean Higher Low Water (MHLW) ‐ +1.0 m
Mean Lower Low Water (MLLW) ‐ +0.5 m
Mean Sea Level (MSL) ‐ +1.3 m
Tidal were measured at 15 minute interval for a month during April – May 1998
by installing a tide gauge at Oil Berth No. 8. The maximum tidal range observed
during the spring tide was 2.7 m and the minimum range during neap tide was
0.51 m.
At present, an electronic tide gauge has been installed at Berth no 8 and tide
levels are captured by VTMS at the signal station.
2.4.6 CURRENTS
The currents in the region outside the sheltered harbour have been found to be
generally less than one knot, during fair season and are mainly caused by tidal
ebb and flow. Within the sheltered harbour, indicated currents strengths are of
the order of 30 to 40 cm/sec. During heavy monsoon rains the current pattern is
altered from that during the fair season but the current strengths do not get
appreciably altered.
As part of the field investigations in Vasco Bay, current observation were taken
at two locations (CM1‐15° 26’ 00” N, 73° 48’ 18” E, CM2 ‐ 15° 24’ 21”N, 73° 48’
42” E). A summary of the current measurements is given in Table 2.3.
Table 2‐3 Current Measurement
CM2 (Water
CM1 (Water depth, 7 m)
depth, 3.5 m)
Near Surface Mid depth Near bottom Near bottom
Maximum speed (cm/cc) 68 31 29 57
Minimum Speed (cm/cc) 0 0 0 0
Predominant Direction ESE‐WNW ESE‐WNW ESE‐WNW ESE
Measurements at open location (CM1) indicate that the predominant flow is in
the ESE‐WNW direction, while at the location (CM2) close to the shore, the
predominant direction is ESE. The flow of currents is predominantly due to the
tidal currents. During flood water, flow is towards Zuvari River while during the
ebbing, the reversal of flow takes place.
The maximum current velocity was observed as 68 cm/sec.
Presently current measurements near berth no 8 are captured by VTMS at the
signal station. The current values are printed and sent to MPT twice a day.
2.4.7 WAVE CONDTIONS
A number of wave observations have been made at and around Mormugao
harbour at different times, including both ship observations & those made from
the shore and the measured wave heights by installing a wave rider buoy.
Mormugao harbour on the Southern side where berths are located is protected
by a breakwater and mole and generally it is the waves from directions between
SW and NW that could affect the tranquility in the harbour. The deep water
waves from NW generally have a small % probability exceedence and do not
affect harbour tranquility significantly since their heights get reduced by the time
they reach the harbour.
HOWE during their master plan study constructed the wave rose diagram from
the visually observed wave heights during the period 1949 to 1962, from the area
bounded by Latitude 10° N to 20° N and Longitude 70° E to 80° E. These wave
analyses indicated that the yearly average probability of exceedence of the wave
height of 2 m for the Westerly direction would be
Direction Exc . Hs = 2 m
SW 4.7%
W 4.5%
NW 0.4%
Frederic R Harris (FRH) during their master plan study in 1997 carried out
further additional wave climate analyses based on wave observations made
during the period 1961‐1980 bound by Latitude 13° N to 16° N and Longitude 70°
E to 74°E and arrived at the following results for deep water wave climate and
wave heights at harbour entrance;
Table 2‐4 Deep Water Wave Climate (Probability of exceedence in % of time)
HS= 1.0 m 2.0 m 3.0 m 4.0 m 5.0 m 6.0 m
SW 12.2 8.7 4.7 2.2 0.8 0.3
W 22.0 14.4 8.1 3.6 0.7 ‐
NW 9.6 2.5 0.7 0.3 ‐ ‐
Due to refraction, shoaling and breaking, the wave direction and wave height
will change while traveling from deep water to the harbour entrance. Generally
by refraction the waves from NW turn to WNW. Waves from W and NW reduce
in height. All wave conditions higher than Hs = 4 m are reduce by wave
breaking. The operational wave climate at the harbour entrance in presented here
below;
Table 2‐5 Operational Wave Climate at Harbour
(Probability of exceedence in % of time)
HS= 1.0 m 2.0 m 3.0 m 4.0 m
SW 12.2 8.7 4.7 2.2
W 21.6 13.6 7.4 3.0
NW 8.4 2.0 0.6 0.2
The extreme wave climate at the harbour entrance is as follows:
Frequency of occurrence Hs
10/ Year 4.7 m
1/ Year 5.0 m
1/10 Year 5.4 m
1/100 Year 5.8 m
Extreme wave conditions at harbour entrance will occur mainly during the
monsoon period. The period of the extreme waves varies between T=7S and 13S.
During the last 4‐5 years since the installation of VTMS, MPT is measuring the
wave heights near the approach channel at a water depth of 10 m by installing a
wave rider buoy. The VTMS captures these measured wave heights at the signal
station. Twice a day, the recorded values are sent to MPT for their records.
It is also understood that National Institute of Ocean Technology (NIOT),
Chennai has installed a wave rider buoy in Mormugao port waters and the
observations are maintained by NIOT.
2.4.8 RELATIVE HUMIDITY
The region is generally humid throughout the year. The morning and evening
relative humidity values are averaged over a thirty year period, as shown in
Table3.

Table 2‐6 Average Monthly Relative Humidity
Month Morning (08.30 IST) Evening (17.30 IST)
January 78 54
February 79 59
March 78 63
April 74 65
May 74 67
June 86 81
July 90 86
August 89 84
September 90 81
October 85 74
November 75 62
December 72 56
Source: IMD
June to September is the most humid months of year with consistently high
humidity both in the mornings and in the evenings.

2.4.9 VISIBILITY
The visibility is generally good. Based on the data of 20 years, the yearly average
morning and evening visibility is as given in Table 3.7.
Table 2‐7 Number of Days per Year with Visibility
Upto 1 km 1‐4 km 4‐10 km 10‐20 km Over 20 km
M E M E M E M E M E
3.4 0.1 4.7 4.1 28.1 21.3 323.6 324.7 5.2 14.8
Source: IMD
Legend: M‐0830 HRS and E‐1730 HRS.
2.4.10 SEISMIC CONDITIONS
The area falls in most active seismic zone as per IS 1893 (Zone III). This will be
considered at the time of detailed design.

3 DRAWINGS
3.1 CROSS SECTION OF BERTH
GOTTWALD OFFER
G HSK 8332 B
Portal Harbour Crane
Technical Description
Table of Contents Page
1 Introduction 3
2 Portal chassis 4
2.1 Steel structure ............................................................................................................ 4
2.2 Portal staircase .......................................................................................................... 4
2.3 Rail-mounted travel gear ............................................................................................ 4
2.4 Motors ........................................................................................................................ 4
2.5 Operational brakes and holding brakes ...................................................................... 4
2.6 Travel gear control system ......................................................................................... 4
3 Superstructure 5
3.1 Protective Housing ..................................................................................................... 7
3.2 Diesel-Generator System (optional) ........................................................................... 7
3.3 Hoist........................................................................................................................... 8
3.4 Slewing Gear.............................................................................................................. 9
3.5 Luffing Gear ............................................................................................................... 9
3.6 Pressure Oil Unit ...................................................................................................... 10
3.7 Maintenance Hoist Winch......................................................................................... 10
3.8 Counterweight .......................................................................................................... 10
4 Tower/Boom System 11
4.1 Tower ....................................................................................................................... 11
4.2 Luffing Boom ............................................................................................................ 12
4.3 Access to Tower Cab ............................................................................................... 12
5 Tower Cab 13
5.1 Controls and Indicators ............................................................................................ 14
5.2 Visumatic® – Crane Management System ................................................................ 14
6 Hook Rotator 15
7 Safety Equipment 15
7.1 Safe Load Indicator .................................................................................................. 15
7.2 Limit Switches .......................................................................................................... 15
7.3 Safety Valves ........................................................................................................... 15
7.4 Locking of Superstructure ........................................................................................ 15
7.5 Storm Safety Anchors .............................................................................................. 16
7.6 Anemometer ............................................................................................................ 16
7.7 Emergency Stop....................................................................................................... 16
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G HSK 8332 B
7.8 Emergency Escape Ladder ...................................................................................... 16
7.9 Smoke detection system .......................................................................................... 16
8 Electrical Equipment 17
8.1 Shore Power Supply via a Cable Reel...................................................................... 17
8.2 Electrics Room ......................................................................................................... 17
8.3 Central Computer..................................................................................................... 17
8.4 Lighting .................................................................................................................... 17
8.5 Operating Hours Counter ......................................................................................... 18
8.6 Video Camera Assistance ........................................................................................ 18
8.7 Radio Remote Control.............................................................................................. 18
9 Surface Protection 18

G HSK 8332 B
1 Introduction
Gottwald Mobile Harbour Cranes and Portal Harbour Cranes are slewing boom cranes. They
were introduced to the market in 1956 and have been developed continually since then. With
maximum lifting capacities of up to 200 tonnes and working radii of up to 56 metres, Gottwald
cranes are used to serve ships of all types and sizes.
A Gottwald Portal Harbour Crane comprises four main assembly groups:
Portal chassis
superstructure
tower
boom
The superstructure serves as a protective housing for the drives, control system and power
generation equipment. The closed tower transmits forces between boom and superstructure
and provides the crane operator with comfortable, weather-protected access to the tower cab.
The boom is constructed as a torsionally stiff tubular-lattice structure.
The tower cab is the crane operator's ergonomically designed workplace and affords an
excellent view of the work area. All the crane functions can be controlled from the tower cab. In
addition, the crane is fitted with radio remote control.
Gottwald cranes are designed and manufactured to international standards and guidelines and
in accordance with the state of the art. This, together with Gottwald's long experience of crane
manufacture, provides the basis for many years of reliable, high-performance crane operation.

G HSK 8332 B
2 Portal chassis
The sub-structure is designed as a travelling rail-mounted portal to support the slew ring of the
superstructure.
2.1 Steel structure

The welded steel structure is based on a torsion-proof box girder construction. The structure is
designed to support the slew ring and the rail-mounted travel gears. The portal main girder is
connected to the portal side girders by bolted joints. The portal main girder is equipped with a
platform which provides access to the superstructure.
2.2 Portal staircase

A staircase at one side of the portal chassis provides access to the access platform on the
portal main girder.
2.3 Rail-mounted travel gear

Each corner of the crane is equipped with eight wheels. Each travel gear corner consists of four
twin rocker sets attached to a rocker beam system by means of pin support assemblies.
2.4 Motors
Some of the twin rocker sets are equipped with travel gears. The travel gears consist of a 3-
phase asynchronous motor with an integrated brake combined with a reduction gear. The
output shaft of the reduction gear is directly connected with the driven wheel. Each motor drives
one wheel.
2.5 Operational brakes and holding brakes

Reducing the crane travel speed (operational braking) is carried out electrically without causing
any friction or wear. As soon as the crane travelling gear has come to a standstill the holding
brakes integrated in the drive motors will prevent the crane from unintended travel motions.
Additional rail clamps are engaged as soon as the crane main switch is switched off.
2.6 Travel gear control system

The travel gear is controlled from within the tower cabin. The control system includes the drive
unit and the braking function. The travel gear can be accelerated steadily in both directions to
maximum speed. An alarm sounds during travel motion.

G HSK 8332 B
3 Superstructure
The superstructure is a torsionally stiff welded steel load-bearing structure designed to carry all
the forces and moments occurring in crane operation. It has two floors. With a headroom of
2.5 m (8’-2”) on each floor, it provides ample room for easy access to all electrical and
mechanical components. The superstructure accommodates:
the diesel-generator system (optional)
hoists
slewing gear
the pressure oil unit
the electrics room
the counterweights.
The two floors of the superstructure are divided into a number of different rooms:
Lower floor:
diesel-generator room (optional)
machinery room for the slewing gear
Upper floor:
machinery room for the hoists and the pressure oil unit
electrics room
A platform at the front of the superstructure provides safe access from the portal platform to the
superstructure. The superstructure is accessed via lockable doors. The integral stairwell
provides comfortable access to the rooms of the upper floor and to the stairway leading to the
tower cab.
The superstructure is illuminated with fluorescent lamps, half of which serve also as emergency
lighting.

G HSK 8332 B
Diesel-generator
system (optional)
Slewing gears
Stairwell
Access platform
Figure 3: Schematic representation of the superstructure – lower floor
Rope drums
Electrics room
Hydraulic pump
Hoist reduction gear units
Hoist motors Luffing cylinder

maintenance
platform
Figure 4: Schematic representation of the superstructure – upper floor

G HSK 8332 B
3.1 Protective Housing

The protective housing protects all components from environmental influences; it also protects
the environment from noise emissions. The protective housing is made up of the steel structure
of the superstructure together with side panelling made of coated composite plates and a roof
made of aluminium plates. The rope outlet on the roof of the superstructure is protected against
ingress of rain and dust by means of rubber seals. Water ducts are provided for rainwater
removal.
The side walls can be removed easily for replacement of individual drive units.
3.1.1 Communication System

The crane is equipped with a communication system having headphones and microphones,
which can be connected in:
the diesel-generator room
the machinery room for the hoists and pressure oil unit
the machinery room for the slewing gear
the electrics room
the tower cab
The system is supplemented with external loudspeakers and an amplifier with microphone in
the tower cab. An additional intercom device is located at the portal chassis located near the
ground.
3.1.2 Ventilation System

The superstructure is provided with forced-air ventilation. Fresh air with a low dust content is
sucked in at the right side of the tower and fed into the superstructure via an air duct integrated
in the tower. In the superstructure, the air is distributed to the two machinery rooms and to the
diesel-generator room. The fresh air serves both to cool the drive units and as combustion air
for the diesel engine. The heated exhaust air is removed in an upward flow through the closed
tower and escapes via air outlet openings.
The elevated air intake position and the slight positive pressure in the superstructure minimise
the dust load on the drive units.
3.2 Diesel-Generator System (optional)

The electric power for the crane drives is generated by a diesel-generator system. The diesel
generator unit is adequately dimensioned so that all crane functions can be carried out
simultaneously.
The diesel engine is connected to a three-phase generator. For quick replacement, the diesel-
generator unit is mounted on a sliding frame, which can be removed sideways from the
superstructure using standard port equipment.

G HSK 8332 B
The control unit for the diesel engine is installed on the engine and equipped with start and stop
buttons, key-operated ignition and a digital display for:
engine oil pressure
coolant temperature
rev counter
operating hours counter
battery voltmeter
The starter batteries with the main switch are also located in the diesel-generator room.
3.2.1 Day Tank

The diesel engine is operated with fuel from the day tank, which is also located in the diesel-
generator room. The day tank is automatically filled with fuel from the main fuel tank located in
the portal structure.
The automatic filling is controlled with the aid of a number of sensors in the day tank. As an
additional safety facility, a return line runs from the day tank to the main fuel tank to prevent the
former from overflowing.
3.3 Hoist
The hoist assembly comprises two hoists, each having a modular design. One hoist serves as
holding gear, the other opens and closes the four-rope grab. Each hoist comprises:
DC motor
spring-loaded disc brake
completely enclosed reduction gear unit
milled rope drum.
The rope drums, reduction gear units and hoist motors are arranged in such a manner that all
the maintenance points are easily accessible. The ropes are coiled in one layer on the rope
drums in order to keep wear low. Two ropes are coiled on each drum.
The rope ends are connected directly to the grab or to the hook rotator, i.e. hook speed equals
rope speed.
A horizontal load path during luffing is achieved by triple reeving of the ropes between tower
and boom head.
3.3.1 Hoist Lubrication

The hoist reduction gear units are oil-immersed. The oil level is monitored.
3.3.2 Hoist Brake

The hoists are braked electrically by the hoist motors. When the hoisting speed is near zero,
the spring-loaded hydraulically released disc brakes are applied automatically. These brakes
also act as emergency brakes in the event of a power supply failure.

G HSK 8332 B
3.3.3 Hoist Control
The electric motor is a separately excited DC shunt motor. The hoist motor is controlled by
means of thyristors connected in an inverse-parallel arrangement. The DC drive system
provides smooth acceleration and deceleration of the hoisting motion. It thus protects the
mechanical components and the steel structure from fatigue. The maximum possible hoisting
speed is automatically increased with reduced load.
In crane operation with the hook rotator, both hoists are electronically synchronised.
3.4 Slewing Gear

With the slewing gear, the superstructure can be slewed infinitely. The slewing gear has a
modular design and comprises:
DC motor
elastic coupling
disc brake
three-row roller bearing slew ring
fully enclosed planetary reduction gear unit.
The drive pinion of the planetary gear unit engages with the internal toothing of the slew ring.
3.4.1 Slewing Gear Lubrication

The slewing reduction gear unit is oil-immersed. The roller bearing slew ring and the toothing
are lubricated by means of a central lubrication system.
3.4.2 Slewing Gear Brake

The slewing motion is braked electrically. When the slewing gear has been brought to a
standstill, the spring-loaded hydraulically released disc brake is applied automatically. This
brake also acts as an emergency brake in the event of a power supply failure.
3.4.3 Slewing Gear Control

The electric motor is a separately excited DC shunt motor. The slewing gear motor is controlled
by means of thyristors connected in an inverse-parallel arrangement. The DC drive system
provides smooth acceleration and deceleration of the slewing motion. The maximum slewing
speed depends on the boom position and is controlled automatically.
3.5 Luffing Gear

The boom is luffed in and out by means of a hydraulic differential luffing cylinder that holds the
boom in position. The cylinder is mounted below the boom. Brake valves control the cylinder
movement. For safety reasons, pipe-break valves are fitted.
For maintenance work, the valve block on the luffing cylinder can be accessed easily from a
platform on the superstructure.

G HSK 8332 B
3.5.1 Luffing Gear Drive
The pressure oil unit in the superstructure supplies the luffing cylinder with pressurised oil for its
operation.
3.5.2 Luffing Gear Control

Acceleration and deceleration of the luffing motion are controlled smoothly and in an infinitely
variable fashion by means of valves and by alteration of the volumetric flow rate of the oil.
3.6 Pressure Oil Unit

The pressure oil unit supplies pressurised oil to the luffing gear. It comprises:
a three-phase squirrel-cage motor
an elastic coupling
an axial piston pump.
The axial piston pump has an adjustable oil displacement. The displacement is adapted as
necessary during crane operation.
3.7 Maintenance Hoist Winch

In the upper part of the double-deck machinery house, an electric chain winch with electric
driven trolley on a rail is installed to facilitate lifting of tools, parts and oil drums from the ground
into the machinery house. It has a lifting capacity of 1,600 kg (approx. 3,500 lbs).
3.8 Counterweight
The counterweight is mounted in a positive-fitting manner in T-rails at the rear of the
superstructure.

G HSK 8332 B
4 Tower/Boom System
The high boom pivot point on the tower allows the crane to be positioned very close to the ship
without risk to ship freight, ship superstructure or crane components.
The elevated position of the tower cab offers an excellent view of the entire work area and into
the ship's hold.
Cable reel (optional)
Rope pulleys on
boom head
Rope pulleys on
tower head
Tower cab
Boom root bearing
Luffing cylinder Stairway to

tower cab
Figure 5: Schematic representation of the tower/boom system
4.1 Tower
The tower is a torsionally stiff, welded steel structure. It has a closed design up to the tower
cab. The transmission of forces and moments to the superstructure takes place in a uniformly
distributed manner over the entire circumference of the tower.

G HSK 8332 B
4.1.1 Rope Pulleys
A rope pulley set is provided on the tower head. Rope guides prevent the hoist ropes jumping
out of the pulleys. The rope pulleys run in anti-friction bearings and are of a low-maintenance
design. Grease nipples are, however, provided for lubricating the bearings.
The rope pulleys can be accessed easily via ladders and platforms.
4.2 Luffing Boom

The luffing boom is constructed as a torsionally stiff, welded tubular-lattice structure with two
upper chords and one lower chord. The boom comprises the boom root and the boom head,
which are connected together by a flange connection that remains immovable even in the long
term.
4.2.1 Boom Root Bearing

The boom root is mounted in plain bearings on the tower. A maintenance platform provides
easy, safe access to the boom root bearing.
4.2.2 Rope Pulleys

A rope pulley set is provided on the boom head. The design of the rope pulley set is the same
as that of the rope pulley set on the tower head. The distance between the rope pulleys is
selected such that load is stabilised below the boom.
4.3 Access to Tower Cab

Weather-protected access to the tower cab is provided via the closed tower. The tower cab can
be reached easily via wide, safe stairways having a stair angle of 50°. Spacious platforms
facilitate maintenance work.

G HSK 8332 B
5 Tower Cab
The crane operator controls all the functions of the crane from a spacious, ergonomically
designed tower cab. Large windows and the cab position high on the tower provide an excellent
view of the work area and the ship's holds.
The tower cab is fitted with safety glass windows. The windows are arranged in such a manner
that they are easy to clean from inside and outside.
The remaining, unglazed wall areas of the tower cab are thermally insulated and fitted on the
outside with stainless-steel plates. The cab is fitted with:
windows of tinted safety glass
a front window with infinitely variable opening
noise-reducing interior panelling
upholstered operator seat, which is adjustable in the vertical and horizontal directions
controls and indicators
adjustable air nozzles
sun blinds on the side, roof and front windows and on the door
air conditioner
electric heater
wiper/washer system for the front and roof windows
interior lighting
electric socket
electric horn
internal and external communication system
ashtray
AM/FM radio with CD player.
Air conditioner
Window wiper and

washer system
Video monitor
Visumatic® monitor
Figure 6: Schematic representation of the tower cab

G HSK 8332 B
5.1 Controls and Indicators

The controls and indicators for all crane functions are located in control panels on both sides of
the operator seat and on the Visumatic®.
The controls comprise light switches and control levers and switches for all main and auxiliary
crane functions.
5.2 Visumatic® – Crane Management System

Visumatic®, Gottwald's crane management system, displays all the crane functions in a
structured, easy-to-understand form on a monitor near the crane operator seat. The individual
functions are indicated by coloured pictograms and are selected with function keys on the
monitor.
All the data required for operating and monitoring the crane are shown on the Visumatic®
monitor. These data include:
check list with status indicator for crane operations
actual and limit values for load, radius and hoisting height
wind speed
fuel level
operating mode (hook, spreader or grab operation)
diagnostic messages
support for fault finding and remedying
indication of remaining operating hours until end of maintenance interval
diesel engine diagnostic system
statistics for diagnostic messages and performance data.

G HSK 8332 B
6 Hook Rotator
For hook operation a lifting gear instead of the grab can be fitted to the ends of the ropes.
The lifting gear comprises a beam from which a ramshorn hook equipped with safety catches is
suspended by means of a universal joint. The hook is manually rotatable on a roller bearing.
7 Safety Equipment
The safety equipment installed complies with the applicable EU directives. Additional safety
equipment further enhances operational safety.
7.1 Safe Load Indicator

The crane is equipped with an automatic safe load indicator that ensures its safe operation.
The system indicates the actual load on the ropes and the actual radius of the boom. As soon
as the permissible load is reached, motions that would increase the load moment are disabled
and an audible alarm is sounded in the tower cab.
7.2 Limit Switches

The hoisting and lowering motions of the crane are limited by electronic limit switches. In the
pre-limit switch range, the speed of the hoisting motion is reduced. When the switch-off point is
reached, the hoisting motion is stopped.
For the electronic limit switching of the hoist, the hoisting height is detected by two redundant
systems. The values are compared in a computer. As a check, the comparison is also
performed in parallel in a second computer.
The limit switching of the luffing gear functions in the same manner as that of the hoist.
7.3 Safety Valves

The luffing cylinders are equipped with pipe-break valves that hold the cylinders in position
should a leak occur.
Pressure limiting valves protect the hydraulic circuits from excessive pressure.
7.4 Locking of Superstructure

During storms, the superstructure and the portal chassis are locked together mechanically. The
locking / unlocking of the crane is performed from the tower cabin. As soon as both parts are
interlocked the slewing gear drive is disabled.

G HSK 8332 B
7.5 Storm Safety Anchors
In case of high wind speeds the crane has to be locked to the ground to prevent the crane from
drifting caused by wind. For this the portal structure is equipped with one storm safety device at
each side girder which will interlock with an appropriate device in the quay structure.
7.6 Anemometer
An anemometer is located on the tower head. The wind speed is shown on the Visumatic®
monitor. If the allowed wind speed is exceeded, an audible alarm will be sounded in the tower
cab.
7.7 Emergency Stop

In case of danger to staff in the work area or to the crane itself, the motions of the crane can be
stopped immediately by actuating an emergency stop switch.
Emergency stop switches are mounted in the tower cab, in the superstructure and in the
electrics room. When one of these switches is actuated, all crane motions are stopped
immediately.
Further emergency stop switches are mounted at the sides of the portal chassis. When one of
these emergency stop switches is actuated, all crane travel motions are stopped immediately.
7.8 Emergency Escape Ladder

Mounted on the platform of the tower cab is an emergency escape ladder. If the stairways
inside the tower cannot be used, the tower cab can be evacuated via the emergency escape
ladder.
7.9 Smoke detection system

The crane will be equipped with a smoke detection system which will detect smoke in the
following areas:
Electrics room
Diesel engine room
Machinery house
Tower cabin
The signal will be provided both audible and via the Visumatic© system in the tower cabin to
the crane driver. Additionally an audible siren will be mounted in the tower.

G HSK 8332 B
8 Electrical Equipment
The main drives of the crane are driven by means of electric motors. This drive concept, which
is the most wide-spread and commonly used drive concept in port technology applications,
offers the following advantages:
low operating and maintenance costs
reliable operation even in continuous, multi-shift operation
reliable operation under extreme climatic conditions
long machine-unit service lives with unvarying high efficiency
easy service and maintenance.
Thyristor converter units convert the alternating current to direct current for the hoist and
slewing gear drives. The DC drive system provides smooth acceleration and deceleration of the
crane motions.
8.1 Shore Power Supply via a Cable Reel

A motor-operated cable reel fitted with a single reel is installed on the portal chassis. The cable
reel is fitted with a single trailing cable. The quay ends of the cable are not fitted with a plug-in
connector. On customer request, medium voltage connecting plug and a medium voltage
socket for the shore mains can be supplied.
The feed voltage is converted into the correct voltage for the crane mains via a dry-type
transformer. This transformer is located in a separate compartment located at the portal
chassis.
8.2 Electrics Room

The closed, lockable electrics room is located in the superstructure. Accommodated in this
room are the crane control system and the electric control equipment.
The electric control equipment is arranged by function groups. All cables, plugs and terminal
strips are clearly marked so that maintenance work can be performed easily.
An air conditioner and a heater in the electrics room prevent problems due to moisture and
make it possible to carry out maintenance work safely and reliably under all weather conditions.
8.3 Central Computer

The programmable logic controller of the crane is installed in the electrics room. It detects and
monitors all electric signals and diagnostic messages via a bus system. In addition, data is
exchanged between the controller, the crane drives and the tower cab via a high-speed bus
system.
8.4 Lighting
The tower cab, all rooms of the superstructure, and the entrances, stairways and platforms are
illuminated by fluorescent lamps. Half of these fluorescent lamps serve also as emergency
lighting. Thanks to the installed lighting, it is possible to walk safely on and in the crane, and to
perform maintenance work without difficulty, when it is dark outside.

G HSK 8332 B
Floodlighting is provided for illumination of the work area in night operation of the crane. Lights
are mounted on the boom head, below the boom, on the front of the tower and on the rear of
the tower cab platform.
8.5 Operating Hours Counter

The operating hours counters record the operating hours of the various crane drives.
8.6 Video Camera Assistance

The crane is equipped with a camera system that assists the crane operator during loading and
unloading of cargo. The image captured by a video camera on the boom head is displayed on a
monitor in the tower cab. The monitor is mounted in a clearly visible position close to the
operator seat.
8.7 Radio Remote Control

All the crane functions can be controlled with the radio remote control. The control unit is
portable, robust and weatherproof. The radio remote control is equipped with displays that
show, among other things, the operating mode, radius and lifting capacity. The individual
functions are indicated with the same symbols and pictograms as are used in the tower cab.
With the radio remote control, the crane can be moved easily from any location on the pier for
maintenance purposes. Miscommunication between the crane operator and quay staff during
repair and maintenance work can thus be avoided.
9 Surface Protection
All load-bearing parts are sandblasted and painted using proven methods. These methods
meet the requirements of a salt-laden, marine environment.
Subject to change without notice.

Mobile Harbour Crane
G HSK 8332 B
Main Technical Data
Table of Contents Page
1.0 MAIN DIMENSIONS .............................................................................................................. 2

2.0 WEIGHTS .............................................................................................................................. 2
3.0 MAIN DRIVE .......................................................................................................................... 2
4.0 HOIST.................................................................................................................................... 2
5.0 SLEWING GEAR ................................................................................................................... 3
6.0 LUFFING GEAR..................................................................................................................... 3
7.0 GANTRY................................................................................................................................ 3
8.0 AMBIENT CONDITIONS........................................................................................................ 3
9.0 STABILITY REQUIREMENT (PERCENTAGE OF TIPPING LOAD)....................................... 3
10.0 CLASSIFICATION OF CRANE AND MECHANISMS ............................................................. 4
11.0 LIGHTING .............................................................................................................................. 4
12.0 SURFACE TREATMENT ....................................................................................................... 5
Project 15 044 Page 1 von 5 8228 – Ra – 03/10 – TD – G HSK 8332 B

G HSK 8332 B
1.0 Main Dimensions

Length of gantry incl. buffers approx. 24.8 m
Width of gantry incl. cable reel approx. 15.0 m
Base (length, width) 13.0 m x 13.5 m
Tail radius 7.5 m
Height of boom pivot point approx. 30.6 m
Crane operator viewing height approx. 34.2 m
Boom length 53.0 m
Maximum radius 50.0 m
Minimum radius 12.0 m
Hoisting height on hook above quay 11 m to 47 m radius 42.0 m
up to 50 m radius 36,5 m
Hoisting height on hook below quay 12.0 m
2.0 Weights
Counterweight 135.0 t
Total weight of operational crane approx. 620.0 t
3.0 Main Drive

Type of drive system Electric power supply by harbour mains
Voltage Medium Voltage > 1,5kV
Cable length on cable reel approx. 150 m
Backup Drive:
Manufacturer Cummins
Model QST30-G5
Combustion type Diesel
Cooling Water
Nominal power 1.112 kW at 1.800 rpm
Number of cylinders 12
4.0 Hoist
Number of rope drums 2
Number of ropes 4
Hoisting speeds:
to 32.0 t 140.0 m/min
50.0 t 100.0 m/min
63.0 t 80.0 m/min
80.0 t 62.5 m/min

G HSK 8332 B
5.0 Slewing Gear

Number of slewing gear drive units 3
Slewing speeds:
to 63.0 t to 1.6 rpm
to 80.0 t to 0.68 rpm
Maximum peripheral speeds at boom head to 63.0 t 300.0 m/min
to 80.0 t 110.0 m/min
6.0 Luffing Gear

Luffing speeds: to 63.0 t 0-80.0 m/min
to 80.0 t 0-34.0 m/min
7.0 Gantry
Rail span 13000 mm
Distance of truck centers 13500 mm
Clearance height of portal 6200 mm
Number of wheels 32
Number of driven wheels 12
Travelling speed 30 m/min
Diameter of wheels 630 mm
Wheel distance 1000 mm / 1250 mm
Rail loads:
Maximum load per corner approx. 320 t
Maximum load per wheel approx. 40 t
8.0 Ambient Conditions

Permissible wind speeds:
Crane in operation to 24.4 m/s (9 Beaufort)
Crane in travel operation to 24.4 m/s (9 Beaufort)
Crane out of service to 46.1 m/s (14 Beaufort)
Crane anchored (by storm anchors) to 50.0 m/s
Permissible ambient temperatures: * minimum -20° C

maximum +45° C
9.0 Stability Requirement (Percentage of Tipping Load)

Normal-load operation / heavy-load operation < 50 %
Grab operation < 50 %

G HSK 8332 B
10.0 Classification of Crane and Mechanisms

Classification in accordance to: FEM 1.001, 3rd edition, 1998
10.1 Crane Classification

Grab operation 50.0 t A8
Grab operation 63.0 t up to 34m A8
Grap operation 63.0 t up to 40m A7
Heavy-load operation 80.0 t A6
10.2 Classification of Mechanisms

Hoist:
Grab operation 50.0 t M8
Heavy-load operation 80.0 t M5
Slewing gear:
Luffing gear:
Travel gear: M4
11.0 Lighting
Boom head * Sodium vapour lamp 1 x 1000 W
Bottom of boom * Sodium vapour lamp 2 x 1000 W
Front of tower * Sodium vapour lamp 2 x 400 W
Rear of cab platform * Sodium vapour lamp 1 x 400 W

G HSK 8332 B
12.0 Surface Treatment

Surface treatment of the steel structure: EN ISO 12944
Surface preparation: Sa 2.5 (ISO 8501-1)
Edge protection Two-component epoxy resin with micaceous iron ore
Primer coat: Two-component epoxy resin ≥ 60 μm
Intermediate coat: Two-component epoxy resin ≥ 60 μm
Top coat: Two-component acrylic-polyurethane ≥ 50 μm
Total coating thickness: ≥ 170 μm
Subject to technical modification without prior notice.

GOTTWALD Portal Harbour Crane
G HSK 8332 B
Lifting Capacity Chart

Rail Span 13000 mm
Capacities [t]
Radius
Heavy Lift Grab Grab Grab
[m] on hook on ropes (A7) on ropes (A8) on ropes (A8)
(50%)* (50%)* (50%)* (50%)*
12 80,0 63,0 63,0 50,0
13 80,0 63,0 63,0 50,0
14 80,0 63,0 63,0 50,0
15 80,0 63,0 63,0 50,0
16 80,0 63,0 63,0 50,0
17 80,0 63,0 63,0 50,0
18 80,0 63,0 63,0 50,0
19 80,0 63,0 63,0 50,0
20 80,0 63,0 63,0 50,0
21 80,0 63,0 63,0 50,0
22 80,0 63,0 63,0 50,0
23 80,0 63,0 63,0 50,0
24 80,0 63,0 63,0 50,0
25 80,0 63,0 63,0 50,0
26 80,0 63,0 63,0 50,0
27 80,0 63,0 63,0 50,0
28 80,0 63,0 63,0 50,0
29 80,0 63,0 63,0 50,0
30 80,0 63,0 63,0 50,0
31 80,0 63,0 63,0 50,0
32 80,0 63,0 63,0 50,0
33 80,0 63,0 63,0 50,0
34 78,8 63,0 63,0 50,0
35 76,1 63,0 61,6 50,0
36 73,5 63,0 60,1 50,0
37 71,0 63,0 58,7 50,0
38 68,7 63,0 57,2 50,0
39 66,4 63,0 55,8 50,0
40 64,3 63,0 54,3 50,0
41 62,3 61,9 52,9 50,0
42 60,3 59,7 51,4 50,0
43 58,4 57,5 50,0 50,0
44 56,6 55,5 48,8 48,8
45 54,9 53,5 47,2 47,2
46 53,2 51,7 45,6 45,6
47 51,6 50,0 44,1 44,1
48 50,1 48,2 42,7 42,7
49 48,6 46,6 41,4 41,4
50 47,2 45,1 40,0 40,0
* Indicates the maximum percentual utilization of the tipping load 1.1889.1007-4_a
15 044 - TT - 1.1889.1007-4_a 8228 - Ra - 08.12.08

G HSK 8332 B with 46 m³ grab
start at r = 32,0 m , end at 24 m
s
Combined cycle times Theoretical handling rate calculation
t_acceleration t_constant t_deceleration t_total Start End
Closing grab 15,00 s 15,00 s 0,00 s 15,00 s Theoretical cycle time 77,21 s
Hoisting with load 19,0 m 1,88 s 12,74 s 1,13 s 15,76 s 15,00 s 30,76 s Theoretical cycles/hour 46,62
Slewing with load 93 ° 7,50 s 3,32 s 7,50 s 18,32 s 24,94 s 43,26 s Grab volume 46,00 m³
Luffing with load 8,0 m 5,00 s 1,50 s 4,00 s 10,50 s 24,94 s 35,44 s Filling factor 1,00
Lowering with load 0,0 m 0,00 s 0,00 s 0,00 s 0,00 s 43,26 s 43,26 s Handling rate (volume) 2144,75 m³/h
Opening grab 10,00 s 10,00 s 43,26 s 53,26 s Density (average) 0,80 t/m³
Hoisting without load 0,0 m 0,00 s 0,00 s 0,00 s 0,00 s 53,26 s 53,26 s Handling rate (mass) 1715,80 t/h
Slewing without load 93 ° 7,50 s 3,32 s 7,50 s 18,32 s 53 ,26 s 71,58 s "Through-the-ship" factor (estimated) 0,7
Luffing without load 8,0 m 5,00 s 1,50 s 4,00 s 10,50 s 53,26 s 63,76 s "Through-the-ship" rate 1201,06 t/h
Lowering without load 19,0 m 6,00 s 2,03 s 3,60 s 11,63 s 65,58 s 77,21 s Total handling rate (2 cranes, 20 h) 48042,4 t/d
Cycle times of the drives

0°
Luffing4
Slewing3
R = 32,0 m
93 °
Hoisting2 2,8 m
9,5 m
Grab open/close1
0
R = 24,0 m
0 10 20 30 40 50 60 70 80 90
t[s]
black line: acceleration/deceleration phase
red line: constant speed phase
Project-Number: 15 044 Customer: Adani, India 8228 - Randel 30.03.2010

G HSK 8332 B with 46 m³ grab
start at r = 34,0 m , end at 24 m
s
Combined cycle times Theoretical handling rate calculation
t_acceleration t_constant t_deceleration t_total Start End
Closing grab 15,00 s 15,00 s 0,00 s 15,00 s Theoretical cycle time 68,62 s
Hoisting with load 19,0 m 1,88 s 12,74 s 1,13 s 15,76 s 15,00 s 30,76 s Theoretical cycles/hour 52,46
Slewing with load 75 ° 7,50 s 1,56 s 7,50 s 16,56 s 21,19 s 37,75 s Grab volume 46,00 m³
Luffing with load 10,0 m 5,00 s 3,00 s 4,00 s 12,00 s 21,19 s 33,19 s Filling factor 1,00
Lowering with load 0,0 m 0,00 s 0,00 s 0,00 s 0,00 s 37,75 s 37,75 s Handling rate (volume) 2413,19 m³/h
Opening grab 10,00 s 10,00 s 37,75 s 47,75 s Density (average) 0,80 t/m³
Hoisting without load 0,0 m 0,00 s 0,00 s 0,00 s 0,00 s 47,75 s 47,75 s Handling rate (mass) 1930,55 t/h
Slewing without load 75 ° 7,50 s 1,56 s 7,50 s 16,56 s 47 ,75 s 64,32 s "Through-the-ship" factor (estimated) 0,7
Luffing without load 10,0 m 5,00 s 3,00 s 4,00 s 12,00 s 47,75 s 59,75 s "Through-the-ship" rate 1351,39 t/h
Lowering without load 19,0 m 6,00 s 2,03 s 3,60 s 11,63 s 56,99 s 68,62 s Total handling rate (2 cranes, 20 h) 54055,4 t/d
Cycle times of the drives

18 °
Luffing4
Slewing3
R = 34,0 m
75 °
Hoisting2 2,8 m
9,5 m
Grab open/close1
0
R = 24,0 m
0 10 20 30 40 50 60 70 80
t[s]
black line: acceleration/deceleration phase
red line: constant speed phase
Project-Number: 15 044 Customer: Adani, India 8228 - Randel 30.03.2010

LIEBHERR OFFER
PORTAL SLEWING CRANE
TYPE
LPS 600 Litronic®
VOLUME: TECHNICAL DATAS
for
Adani Mormugao Port Pvt. Ltd.
India
Port of Goa
Offer 1000-2100001153-1
LWN
9/3/2010
--------------------------------------------------------------- Liebherr Werk Nenzing GmbH ----------------------------------------------------------- Page: 1

Liebherr Harbour Mobile Crane,
LPS 600 Litronic
VOLUME: TECHNICAL DATAS
TABLE OF CONTENTS
1 MAIN DATA
1.1 Load Table
1.1.1 Load Capacity Chart
1.2 Operating Speeds
1.3 Weights
1.4 Dimensions
1.5 Environmental Conditions
1.6 Drive System
1.6.1 Cable drum
1.6.2 Slipring connector
1.6.4 Electric provisioning
1.6.5 Auxiliary Genset
1.6.6 Prime mover
1.6.7 Alternative operation
1.7 Four rope grab type VSHC (Verstegen)
1.8 Hopper
1.9 Requirements on Quay
1.10 Hydraulic Oil
2.0 Lighting
2.1 Heating
2.2 Group Classification of Crane and Components
2.3 Documentation
2.4 Protective Coat/Painting

LPS 600 Litronic
1 MAIN DATA
1.1 Load Table
1.1.1 Load Capacity Chart
Hook Operation Four Rope Grab Operation

62,5 % tipping moment 62,5 % tipping moment
utilization utilization
Radius Load on Rope Load on Rope

(m) (t) (t)
12 75.0 75.0
13 75.0 75.0
14 75.0 75.0
15 75.0 75.0
16 75.0 75.0
17 75.0 75.0
18 75.0 75.0
19 75.0 75.0
20 75.0 75.0
21 75.0 75.0
22 75.0 75.0
23 75.0 75.0
24 75.0 75.0
25 75.0 75.0
26 75.0 75.0
27 75.0 75.0
28 75.0 75.0
29 75.0 75.0
30 75.0 75.0
31 75.0 75.0
32 75.0 75.0
33 75.0 75.0
34 72.5 72.5
35 69.9 69.9
36 67.4 67.4
37 65.1 65.1
38 63.0 63.0
39 61.0 61.0
40 58.8 58.8
41 56.9 56.9
42 54.9 54.9
43 53.1 53.1
44 51.3 51.3
45 49.7 49.7
46 48.1 48.1
47 46.5 46.5
48 45.1 45.1
49 43.7 43.7
50 42.4 42.4

LPS 600 Litronic
1.1.2 Travelling Window
For travelling the boom of crane can be positioned on slew angle 0° to 360°.
The maximum load on ropes during travelling is 30t according to following travelling window.
Load on Minimum Maximum

Ropes Radius Radius
(t) (m) (m)
30.0 12.0 20.0
25.0 12.0 22.2
20.0 12.0 24.8
15.0 12.0 27.9
10.0 12.0 31.6
5.0 12.0 36.1
0.0 12.0 42.0
Within the travelling window, a loaded hopper with a total weight of 200t (= 100t dead
weight + 100t life load) can be towed.
1.2 Operating Speeds
* 100 percent infinitely variable speed control from zero to maximum speed
* electronic-controlled acceleration/deceleration, to avoid shocks to crane
and load and to enable smoother speed control
* automatic power output regulators
* slewing, luffing, hoisting can be operated simultaneously at max. speed
ac- / deceleration time

Hoisting / Lowering appr. 1 sec 60.0 m/min with 75 t
73.0 m/min with 63 t
90.0 m/min with 50 t
appr. 3 sec 120.0 m/min with 32 t
Slewing appr. 5-6 sec 0 - 1.6 rpm

280 m/min max speed boom head
360 ° unlimited slewing range
Luffing appr. 2 sec 46 sec with full load from max. to min working
50 m/min radius
average (theoretical
horizontalwithout
speed ac- and
Travelling appr. 6 sec 0 - 30 m/min with load according travelling window
Tail swing radius 7.6 m

LPS 600 Litronic
1.3 Weights
Total weight of crane appr. 555 t

without load attachments (grab)
1.4 Dimensions
Portal basis 14 m x 13 m
Rail span 13 m
(Tensile strength is 700
Rail Tpye ISCR 100 acc. IS 3443 2
N/mm
Portal clearance approx. . 8,5 m
High Voltage Shore Supply available
Entrance inside
Length of boom (centre sheaves) 60.0 m

Overall height (top of tower) approx. 42.6 m
Height of boom fulcrum approx. 25.7 m
Cab height (eye level) approx. 32.1 m
Max. hoisting height (measured at crane rope socket)

above quay at minimum radius approx. 35.0 m
above quay at maximum radius approx. 30.0 m
below quay approx. 25.0 m
Winch configuration 2x72t

Number of winches 2 (2 ropes per winch)
Diameter of hoisting rope 44 mm
Diameter of sheaves at boom head 1000 mm
Ratio between diameter of hoisting rope to sheaves 1 : 22.7
Diameter of rope drum 900 mm
Ratio between diameter of rope to drum 1 : 20.5
Number of wheels per corner (seaside) 10

Number of wheels per corner (landside) 10
Number of total wheels (driven and non-driven) 40
Number of non-driven wheels 12

Number of driven wheels 28
Diameter of the wheels 630 mm

Distance between wheel sets 2000 mm
Distance between wheels 830 mm

LPS 600 Litronic
1.5 Environmental Conditions
Ambient temperature up to +45 °C

Humidity (relative) 97 %
Max. wind speed in operation 24 m/s
Max. wind speed during travelling 24 m/s
Max. wind speed out of operation 42 m/s

For wind speeds exceeding 42m/s the boom must be placed on radius between 20m - 35m, storm anchors
must be used. Load attachments must be lowered onto ground/jetty and have to be lashed to suitable fixing anchors.
Max. design wind speed 50 m/s
1.6 Drive System

The electric equipment complies with the relevant IEC and EN-Standards.
All wiring and cabling is according to relevant DIN/VDE and IEC standards.
In general cables are flame retardant.
The LPS crane is provided with adequate earthing for all electrical systems and equipment.
1.6.1 Cable drum installed on the portal for high voltage power supply
Make Hartmann&König
Type Electric driven magnetic clutch
Cable 3x50+2x25/2+6x2,5
Brand Pirelli / Draka
Working range 120m (to both sides of the feeding point)
Junction Box will be supplied by the customer
Design of the junction box will be supplied by the supplier
Fabrication drawing of the Junction Box will be supplied by
the supplier.
Connection of trailing cable with Junction Box is scope of
supplier because of endtermination kit.
Drawing of a tension releaving drum shall be given by the
supplier but will be bought by customer
Electricity supply stations on shore side: On the berth (exact location to be given by the company)
Cable Supporting Frame/ Bridge: Company to provide G.A drawing (cross section) giving
exact location of the cable guidance/ supporting details.
Make Kraus
Type Endlessrotation

LPS 600 Litronic
1.6.3 Transformer one unit installed on the portal
On the portal a high voltage transformer will be installed by the crane supplier.
Make Lepschi
Type Oilcooled transformer
Input Voltage: 6,6kV / 50Hz
Output Voltage: 690V / 415V 50Hz
Rating: 1600kVA
Three (3) sockets (see "Electric provisioning") will get supplied with electricity from the transformer.
Appropriate outlets will be allocated on the transformer.
The transformer will have a main electricity outlet of 690V for the crane main supply. (2x2x295kW 50Hz)
and an additional outlet of 415V for crane auxiliaries and sockets.
1.6.4 Electric provisioning
Two (2) individually fused (by 63Amp) 415V sockets will be provided on the portal for the power supply
of e.g. maintenance tools.
One (1) 125Amp 415V sockets will be provided on the portal for the power supply of the hopper.
For comunication between hopper and site 6 control wires are provided in the high voltage supply cable.
The 6x2,5 control wires are routed to a junction box/ socket on the portal.
Electric power supply cable and control cable from the Hopper to the Portal will be provided by the customer.
1.6.5 Auxiliary Genset

Customer will provide an appropriate auxilliary Generator set for operating the crane indipendent
from the electric network.
Reqiured voltage rating: 6.6kV / 50Hz
Return energy will be absorbed by the crane aggregate and has not to be absorbed by the Generator set.
1.6.6 Prime mover

Four asynchronous electric motors
Make ABB or equal
Type 315 MLB-4
Duty S6-40% duty
Starter DOL
Max. Crane Power Consumption 1340 kW
Nominal Voltage 690V, 50Hz

Nominal Rating 2x2x295 kW

LPS 600 Litronic
1.6.7 Alternative operation (optional, to be ordered seperately within 2008)
The crane shall be provided with a
Prime mover one Diesel Engine

Make MAN
Type D 2842 LE
Combustion system Diesel
Number of cylinder 12
Cooling system Water
Output on the drive shaft 670 kW at 1900 rpm acc. ISO 9249
Max. torque 3300 Nm at 1300-1700 rpm
Average consumption 208 g/KWh
Starter Bosch QB
Output 9 kW
Dynamo Bosch
Nominal current 140 Amp
Voltage 24 V
If the crane is operated by the Diesel Engine, speeds will be half/ time will be double
1.7 Four rope grab type VSHC (Verstegen)

capacity 44 m³
own weight aprox. 22.4 t
crane load (0,9t/m³) 62 t
Diameter closing rope 44 mm
Diameter pulleys 920 mm
Number of pulleys 4
Material pulleys steel
including one set of closing ropes
Pantanax on cutting edges
Four ballast chains including quick release links
spread limitation system for handling fertilizer of density 1,2t/m³
1.8 Hopper
Hopper will be provided by the cusomer (according to Drawing No.: 1005.201.001/MEC/GL/10)
Distance centre line crane to centre line hopper = 25m
Dead weight hopper = 100t
Capacity 100m³, suitable for storage of COAL (0,8t/m³) or FRM (0,8 & 1,2t/m³)
Towing device (incl. lashing eyes) for the hopper will be provided by the crane supplier
Lashing eyes will be welded on the hopper on-site by the customer

LPS 600 Litronic
1.9 Requirements on Quay
Following loads are relevant: see also attachment

"QUAY LOADINGS", LPS600, ADANI, dated 18.09.08
Weight of the crane incl. counterweight 325.3 t

Weight of the portal; (excl. crane) 230.0 t
Total weight (crane plus portal) 555.3 t
Max. Corner Loading: 393.6 t
Wheels per corner: 10 pieces
Max. Wheel Load: 39.36 t
Towing device (incl. lashing eyes) for the hopper will be provided by the crane supplier
Lashing eyes will be welded on the hopper on-site by the customer
Storm anchors: two storm pins located outside of the rail on the sea side
An extra storm anchor will be provided by the supplier for the fixation on the hopper. Fixation will be done on-site by the customer

LPS 600 Litronic
1.10 Hydraulic Oil
Tank capacity appr. 2100 Litres

See table of lubricants
Oil cooling The hydraulic driven oil cooler is located outside

the machinery room, protected via cover,
cooling medium is fresh air
2.0 Lighting
Appropriate illumination is fitted in - machinery room

- switch cabinet room
- cabs
- access to the crane
Floodlight type high pressure sodium lamps

Position - two on the boom
- one on the tower
Rating (per floodlight) 1000 W - 230 V
Floodlight type halogen

Position - four on the gantry illuminating the rails
Rating (per floodlight) 1000 W - 230 V
Steps from the tower cabin are provided with battery-buffered 24 VDC emergency lights.
Two warning lights and a ringing bell when travelling are standard
2.1 Heating
- Heating of driver's cabins (tower cab 6 kW)

- Heating of switch cabinet room (1 x 2 kW)
- Standstill heating of slipring collector, switch cabinet
- Total installed heating capacity approx. 8 kW.

LPS 600 Litronic
2.2 Group Classification of Crane and Components
Authorities, Regulations F.E.M., DIN, VDE, VDI, IEC, ISO
Classification of crane as a whole in appliance groups
SWL >70t A3
Hook operation
SWL <70t A6
SWL > 52t A7/Q2/U7 or A7/Q3/U6
Grab operation
SWL <52t A8/Q2/U8 or A8/Q3/U7
Duty (Q) results from operation and can be estimated or observed afterwards only!
Classification of individual mechanisms
Hoisting gear (SWL < 75t) M8/L3/T7 or M8/L4/T6

Luffing gear M7/L1/T8 or M7/L2/T7
Slewing gear M7/L1/T8 or M7/L2/T7
Travelling gear M4/L1/T5 or M4/L2/T4
Duty (L) results from operation and can be estimated or observed afterwards only!
2.3 Documentation
Standard scope of delivery includes

- 3 operation/maintenance manuals
- 3 spare parts books
- 3 works certificates

LPS 600 Litronic
2.4 Protective Coat/Painting
I GENERAL - Liebherr QSA 09.000.00-xx
- Cleaning and Substrate Preparation
Solvent Cleaning/Degreasing
Shot Blasting SA 2.5 (ISO 8501-1)
- Surface Profile: Comparator Type "G"
Segment 3-4 (ISO 8503-1)
II CRANE - INTERNAL SURFACES

System: HM12E180AO Film thickness
1 Priming Coat
1.1 2-Pack Zinc Rich Epoxy Primer 60 microns
Interzinc 315 HS
3 Finish Coat
3.1 2-Pack Epoxy Resin-Micaceous Iron Intermed. 120 microns
Amerlock 400C
Light-grey, RAL 9002
----------------------------------------------------------------------------------------------------------------
Total Min. Dry Film Thickness min 180 microns
================================================================
III CRANE - EXTERNAL SURFACES

System: HM13S220AO Film thickness
1 Priming Coat
1.1 2-Pack Zinc Rich Epoxy Primer 60 microns
Interzinc 315 HS
2 Intermediate Coat
2.1 2-Pack Epoxy Resin-Micaceous Iron Intermed. 80 microns
Amerlock 400 C
3 Finish Coat
3.1 2-Pack Siloxan Coating 80 microns
PSX 700
----------------------------------------------------------------------------------------------------------------
Total Min. Dry Film Thickness min 220 microns
================================================================
Note:
Above values are related to primary structure of crane and gantry.
The colour shade for the slewing platform (machinery housing), tower, boom will be according to the customer's choice including logo
All ladders, stairs, walkways, etc. are hot dip galvanised.

LOADCYCLE CALCULATION FOR A LIEBHERR HARBOUR MOBILE CRANE
Project: Adani, Goa Port - LPS 600 17.03.2010
Date:
Crane: LHM 600 2x670
A
Winch: 2 x 70
Drive: E 60Hz B
Load cycle No.
Data of the Cycle:

Outreach vessel side A= 34 m
Outreach quay side B= 25 m
Height hoisting C= 25 m
Height lowering D= 5 m
Turning angle 90 °
Max crane capacity 75,0 t D

Max crane capacity on actual radius 72,5 t
C
Data of the Load Attachment:

Suitable for handling: Coal
with a piled density up to 0,85 t/m³
Grab cpacity 44 m³
Average filling degree 95%
Payload: 35,5 t
Type Cape Size
Dead weight of grab 22,4 t Width 40,5 m
Max SWL during one cycle 57,9 t
Closing stroke appr. 10,3 m

3,0 s (opening time of grab)
In practice different functions will be done simultaneous!
function time superposition start time end time

(sec) (sec) (sec)
1.) Filling of the grab 8 0 8
2.) Hoisting of closed grab 26 8 35
3.) Slewing of the crane 23 Slewing will start after 2/3 hoisting time 26 48
4.) Topping of the crane 12 Topping will be done during slewing 35 47
5.) Lowering of closed grab 6 Lowering will start during slewing 48 54
6.) Opening of grab 8 Opening starts 3 sec before finish slewing 52 60
7.) Hoisting of open grab 5 Hoisting will be started after 3 sec 55 61
8.) Slewing of the crane 15 Slewing will start after 2/3 hoisting time 59 74
9.) Topping of the crane 12 Topping will be done during slewing 58 70
10.) Lowering of open grab 17 Lowering will start after 3/4 slewing time and after topping 70 87
Required time for one cycle: 87
Function in Load Cycle
1.) Filling of the grab

2.) Hoisting of closed grab
3.) Slewing of the crane
4.) Topping of the crane
Function
5.) Lowering of closed grab

6.) Opening of grab
7.) Hoisting of open grab
8.) Slewing of the crane
9.) Topping of the crane
10.) Lowering of open grab
0 10 20 30 40 50 60 70 80 90 100
function time Time [s]
Considering that some movements will be done simultaneously, one cycle requires a time of: 87 sec
87 sec for 1 cycle means 41,4 cycles/hour
41 cycles per hour multiplied with a payload of 35,5 t results in 1470 t/hour TDC
This turnover calculation considers the time required for one cycle projected to one hour, theoretically!
Average turnover capacity "ATC" per day (t/day) is equal to the theoretical discharging capacity "TDC" multiplyed by the operational factor "VF" and the time "T"
ATC = TDC * VF * T
"VF" is an efficiency factor and considers parameters e.g. crane type, grab type and size, crane operator experience, vessel size and type, logistics and operational
circumstances, discharging into a hopper or on a pile, etc.
Also it depends on the amount of hatches which is subject to the size and type of a vessel
Efficiency factor also depends on discharging (sequence and amount) of the different hatchs which have to be carried out according to the instructions of the ship's captain
Discharging of a hatch gets subdivided into three phases: cream didding, free digging and cleaning of a hatch
Based on experience the factor "VF" for a Mobile Harbour Crane is:
VF = 0,65 - 0,7 for Handysize (30.000 DWT, Beam up to 22m); Handymax (50.000 DWT, Beam up to 28m)
VF = 0,7 - 0,75 for Panamax Vessels (up to 100.000 DWT, Beam up to 32m)
VF = 0,75 - 0,8 for Cape Size Vessels (above 100.000 DWT; Beam up to 45m)
Based on practical experience, the factor "T" (hour/day) for a Mobile Harbour Crane is: 22 hr
"T" is a time factor and considers parameters e.g. required daily maintenance on the crane, crane operators endurance, crew of the vessel, logistics and operational
parameters of the termial operator, availability of facilities, capacity of the discharging place, etc.
Based on the experience, the factor "N" considers the amount of cranes working on a vessel
N= 1-2 for Handysize and Handymax
N= 2-3 for Panamax
N= 2-3 for Cape Size Vessels
Average turnover capacity ATC = 45.276 t/day if considering a Cape Size Vessel with 90.000 DWT
A Cape Size Vessel with 90.000 DWT will be unloaded by "N"= 2 LPS600 within 2,0 days.
kWh CONSUMPTION
One cycle requires a time of: 87 sec
Cycles / hour 41 cycles / hour
Consumption per cycle 10,32 kWh / cycle
Standard consumption per hour 427 kWh / hour
Standard consumption per tonnes 0,291 kW / t

Amptpl: Adani Murmugao Port Terminal Private Limited

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ADANI MURMUGAO PORT TERMINAL

PRIVATE LIMITED AMPTPL

CLIENT MORMUGAO PORT TRUST

PROJECT DEVELOPMENT OF COAL TERMINAL AT BERTH NO. 7, PORT OF

TITLE DESIGN BASIS – SHIP UNLOADER (MOBILE HARBOUR CRANE RAIL

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

January 31.6 19.6

February 31.5 20.5

March 32.0 23.2

April 33.0 25.6

May 33.0 26.3

June 30.3 24.7

July 28.9 24.1

August 28.8 24.0

September 20.5 23.8

October 31.6 23.8

November 32.8 22.3

December 32.4 20.6

January 78 54

February 79 59

March 78 63

April 74 65

May 74 67

June 86 81

July 90 86

August 89 84

September 90 81

October 85 74

November 75 62

December 72 56

Table of Contents Page

Project 15 044 Page 1 of 18 8228 – RA – 0310 – TB – G HSK 8332 B

Project 15 044 Page 2 of 18 8228 – RA – 0310 – TB – G HSK 8332 B

Project 15 044 Page 3 of 18 8228 – RA – 0310 – TB – G HSK 8332 B

2.1 Steel structure

2.2 Portal staircase

2.3 Rail-mounted travel gear

2.5 Operational brakes and holding brakes

2.6 Travel gear control system

Project 15 044 Page 4 of 18 8228 – RA – 0310 – TB – G HSK 8332 B

Project 15 044 Page 5 of 18 8228 – RA – 0310 – TB – G HSK 8332 B

Figure 3: Schematic representation of the superstructure – lower floor

Hoist motors Luffing cylinder

Figure 4: Schematic representation of the superstructure – upper floor

Project 15 044 Page 6 of 18 8228 – RA – 0310 – TB – G HSK 8332 B

3.1 Protective Housing

3.1.1 Communication System

3.1.2 Ventilation System

3.2 Diesel-Generator System (optional)

Project 15 044 Page 7 of 18 8228 – RA – 0310 – TB – G HSK 8332 B

3.2.1 Day Tank

3.3.1 Hoist Lubrication

3.3.2 Hoist Brake

Project 15 044 Page 8 of 18 8228 – RA – 0310 – TB – G HSK 8332 B

3.4 Slewing Gear

3.4.1 Slewing Gear Lubrication

3.4.2 Slewing Gear Brake

3.4.3 Slewing Gear Control

3.5 Luffing Gear

Project 15 044 Page 9 of 18 8228 – RA – 0310 – TB – G HSK 8332 B

3.5.2 Luffing Gear Control

3.6 Pressure Oil Unit

3.7 Maintenance Hoist Winch