Saudi Cranes & Steel Works

Jubail – K.S.A.

INSTALLATION PROCEDURE

ERECTION PROCEDURE – METHOD

STATEMENT

1.0 General Description of EOT Crane

2.0 General Instructions

2.1 Check Cargo / Packing List
2.2 Precautions to be taken before and During Lifting

3.0 Crane Installation Procedure

3.1 Erection with mobile cranes
3.2. End carriages with bolted joints
3.3. Bogie type End carriages
3.4. Typical lifting instructions
3.5 Electrical Connections

4.0 Start – Up Procedure

5.0 Typical Erection plan Clipping

Saudi Cranes & Steel Works
Jubail – K.S.A.

INSTALLATION PROCEDURE

1.0 GENERAL DESCRIPTION OF EOT CRANE:

The following description should be read in conjunction with the General arrangement
drawing.

The cranes are of top running double-girder / Single girder type with all motions
electrically operated. The crane mainly consists of Crane Bridge Girder(s), Trolley unit
(Consisting of Hoist/Aux.hoist and cross travel arrangements), end trucks, trolley festoon
system, pendent station (fixed type – in case of an emergency), Radio Remote, Remote
receiver panel & other control panels.

The girder is of box construction and ends are supported & rigidly connected to end truck
at the gantry beam level through end connection plates and high tensile bolts tightened to
required torque. The Hoist unit is a combination of Main hoist and Aux hoist units,
connected rigidly to trolley carriages.

The DG hoist is of electric double reeving type. The Main hoist hook is of Double Crook
and Aux.hoist hook is of Single crook type with safety latches to prevent accidental release
of slings from the hook. The hooks are supported on a block by a thrust bearing in such a
way enabling to rotate 360 degrees.

Trolley is electrically driven and top running type with two driving and two driven wheels,
which runs on trolley rails welded to top of the girders.

End trucks are electrically driven consisting of two drive units. The wheels are straight
tread flange type.

All motors are squirrel cage induction type, and has got Fail safe type Thruster and Electro
-magnetic disc brakes.

Power supply to the crane is effected by the Power feed system. Power supply to trolley
unit is effected by C.T. flat cable festoon system.

The crane is controlled by radio remote and in case of an emergency pendent shall be used.

The Bridge Panel is located near the DSL side. The panel is electrically connected to the
bridge motors, bridge limit switches, trolley Panel, pendent terminal box, and Radio
Receiver. The trolley equipments are connected using festoon systems.
Saudi Cranes & Steel Works
Jubail – K.S.A.

INSTALLATION PROCEDURE

The Crane and trolley are provided with bumpers to restrict LT & CT motions at their
respective extremities by end stoppers. Hoist, cross travel and long travel motions are
provided with electrical safety limit switches to prevent over travel in all directions.

The DSL can be electrically isolated by opening the main switch located near the floor
level / Platform.

2.0 GENERAL INSTRUCTIONS

2.1 Check Cargo / Packing List

All the parts & components should be checked for any damage sustained during
transportation as soon the Cargo is received. Thoroughly consult the respective
packing list and the respective shipping documents.

2.2 Precautions to be taken before and during lifting

Besides the normal construction site (Safety) regulations below are the additional
safety guidelines which must be adhered to:-

1. When using any electrical appliances, it must be ensured that there is no

inflammable gases pervading at the surrounding.

2. Do not commence or continue lifting of crane structures when the wind velocity
exceeds 10 Knots.

3. Do not use slings or lifting attachments which are either in poor conditions or do
not have the required capacity.

4. During lifting of crane structures (especially items that are lengthy and bulky),
ensure that both ends of the structures are attached guiding ropes. These ropes must
be manned sufficiently to control the movements so as to prevent undesirable
swinging and dipping.
Saudi Cranes & Steel Works
Jubail – K.S.A.

INSTALLATION PROCEDURE

3.0 Crane Installation Procedure:

Before starting the Crane installation, the following check points shall be verified.
1. Runway rails shall be verified for correct size
2. Span of the runway rails shall be verified at every column / 2m distance, record
readings and should be equal to the crane span.
3. Reading should be within the tolerance, specified in respective STDs.
4. Installation of Bus Bar can be carryout before/after crane’s installation.

3.1. Erection with mobile cranes :

Erection with One mobile Crane:

When Operating with one mobile crane, lifting ropes are to be adjusted to balance the
girder as shown in Fig. 2. Position the girder so that it may be lifted straight up to the level
of the rail. Attach a guide rope to the girder. Lift the girder to the proper height. Rotate the
girder to the proper position and lower it on to the rails. (Refer Fig. 6)

Erection with two mobile cranes:

When operating with two mobile cranes, follow the procedure in fig. 2 . Verify the capacity
of the mobile cranes, If possible, use one crane to lift the girder and the other to guide the
operation. When using only one crane to lift and the other to guide, precautions must be
taken so that the lifting ropes do not slide. If required, weld supports on to the lower
flange.

3.2. End carriages with Bolted joints:

In this case, the entire crane structure can be lifted in a single lift as per the following
procedure:
1. If the crane delivered in dismantled condition, Align end carriages on the floor and
fasten them to main girders. Use the torque values given on the drawing when
tightening the bolts. Then lift the crane to the runway rails.
OR

1. Lift both of the end carriages on to the rails first, align and secure properly
On the top.
2. The main girders are then lifted separately and the bolt joints are fastened.
Saudi Cranes & Steel Works
Jubail – K.S.A.

INSTALLATION PROCEDURE

3.3. Bogie type End carriages:

1. Fix each bridge girder with their bogies at each end

2. Lift individual Bridge girder fitted with bogie on to the runway rails
3. Use ratchet levers to pull the girders together
4. Now slowly lift bogies to required level and fasten as shown in Fig. 8

3.4. Typical Lifting Instructions:

3.4.1 EOT Crane entry in the Building: (Options-When Roof is closed) :

a- If the Building Entry Door size is enough, but the elevation is higher than the ground
level, Crane in assembled condition can be lifted through Mobile Crane and insert
through Door.
b- If the Building Entry Door size is not enough, then Crane can be lifted through Mobile
Crane and insert through Door, in dismantled condition.
c- If the Building Entry Door size is not enough and whole access area is very much
restricted, then the Roof must be open for full length to insert the whole crane from
Roof Top.

3.4.2 EOT Crane Erection: (Options-When Roof is closed):

a- If the Building Door size is enough like 3m high and 3m wide, but the elevation is
higher than the ground, few equipment like Telehandler can be inserted through
door by using Mobile Crane. Tele handler can be suitably used to erect the crane,
Pics below. Runway beam can be removed, if the bay has restriction for movement.

b- If the Building Door size is not enough for entering any Lifting equipment, then
Building Roof Rafter Beam can be used to mount Chain Blocks to use in lifting
operation (Pics below).

c- If the Building Door size is not enough for entering any Lifting equipment, then
Building Roof can be open for size equal to 4 inch X 4 inch to insert a sling to lift
the Crane (Pics below)
d- If the Building Door size is not enough for entering any Lifting equipment, then
scaffolding of heavier section can be erected inside the Shop, in order to support the
Girder beam lifting, but the Crane Girder weight should not be heavier.
Saudi Cranes & Steel Works
Jubail – K.S.A.

INSTALLATION PROCEDURE

3.4.3 Complete Assembly (Bridge Girders and Trolley assembly):

The general view of crane is shown in the General Arrangement Drawing. The Main heavy
components are Bridge girders fitted with two end carriages on both sides, Hoist & Trolley
Assembly.

Before lifting the crane to install on the runway rail, the orientation of the crane to the
building shall be verified according to the General Arrangement drawing of the crane.

- First Wrap around the crane girders fitted with two end carriages and trolley
assembly with Webbing Slings (at the center when using single crane) at both
ends, and protect sling/ flanges as shown in fig. 3.
- Arrest the Trolley assembly from moving on CT rails during lifting or until
complete lifting process, by means of locking clamps or temporary stopper
welding or tie with rope clamps.
- Now connect the sling with lifting equipment(s).
(Lifting Equipment(s) can be placed inside the shed or outside the shed as per
site conditions)
- Before lifting, check the crane is free from any binding and the lifting path is
free from any obstructions.
- Now lift the assembly slowly, especially when lifting with two mobile cranes
and place it on the runway rails.
- Before releasing slings, check all the wheels are properly seated on rails.

3.4.4 When installing Part by part :

- First lift both End trucks (If they are not Bogie type) and place on LT rails.
Before releasing slings, make sure that the end trucks are properly arrested by
some means from falling down or moving or tilting
- Check straight path of both end trucks and their connection plates
- Now lift Bridge girder as per lifting instructions 2.4.1. Either by using single or
double cranes.
- Place girders on end trucks, and fix end trucks to girder by end connection
plates.

Lifting of Trolley Assembly:

Saudi Cranes & Steel Works
Jubail – K.S.A.

INSTALLATION PROCEDURE

In the Case of Roof Opening:

- Shift the crane manually (Long travel Brakes should be loosen) to left or right
- Place Trolley assembly on the floor level, facing directly the roof opening.
- Now Place the Lifting equipment (mobile Crane) outside of the shed/Plant

- Extend its Boom directly to the roof Opening area and ensure the correct load
angle of the Boom.
- Bring down its hook through the top of the roof opening to the trolley assembly
placed on the floor.
- Proper slings should be arranged to lift the trolley. Lifting legs provided on the
Trolley carriages can be used to lift the assembly.
- Attach now trolley slings or belts to the lifting equipment’s hook.
- Before lifting ensure the correct orientation of the Crab as per GA Drawing.
- Lift the crab slowly until reaches the top level of the girder rails
- Now manually shift the Assembled crane directly below the Crab and slowly
place the trolley assembly (Crab) on CT rails fitted on Crane girders. (Note
before releasing trolley slings, make sure that the bogie connection pins are
properly connected / secured. And also ensure perfect seating of Crab wheel on
its rails.

If roof opening is not possible (mobile crane inside the plant):

If End trucks are bogie type:

- Erect two Bridge girders as explained above, wrap around bridge girder and lift
directly to the top of gantry rails as per rigger signals and slowly place wheels
of end carriages fitted to bridge girder on rails.

- Now move both girders away from each other (Manually – by loosening LT
brakes)
- Place the lifting equipment’s (Mobile) boom in between girders
- Shift the trolley assembly just below and between girders and near to the boom
- Bring down the mobile’s hook to the floor level and attach trolley slings to the
mobile hook
- Slowly lift the crab above the crane rail level
- Now move both girders close and connect both side end carriages with bogie
connector Pins before placing trolley assembly on bridge girders.
- Check the Crab Gauge and Place the Crab on CT rails provided on crane
girders.
Saudi Cranes & Steel Works
Jubail – K.S.A.

INSTALLATION PROCEDURE

Now connect all other accessories as per GA Drawing and electrical

connections as per documents provided.
3.5. Electrical Connections

The crane is already fully wired & tested at shop. For transportation purpose some
external cables may be disconnected and all festoon system cables shall be sent
separately on a track fitted to the bridge girder. All connecting wires shall be
properly identified with their numbers and ferrules. Ensure proper connections as
per Identification marks given on cables with respect to relevant electrical
diagrams. Make connections at panel/junction box terminals as per ferrules /
numbering provided. Connect the Main incoming supply to the Main disconnect
switch fixed near the floor/ Platform, and then the main switch out going to be
connected to the crane bus bar. From this DSL, supply should be connected through
current collectors to the main Panel of the Crane. Make sure all the mechanical &
electrical connections are okay.

4.0 Startup Procedure

Before energizing the Crane, it is very important to follow the following instructions
provided hereinafter.

- Visually inspect the condition of the Crane

- Ensure the mechanical connections and nut bolt connections for required
Torque tightness.
- Ensure the correct supply voltage and frequency
- Energize the DSL by switching ON the Main Isolator Switch provided at floor
Level.
- Check the voltage at the Isolator provided on the cabin fitted to the crane. Then
switch ON main switch provided on the crane panel, and check for correct
voltage in the main panel terminals
- Release all emergency switches and safety interlock if any provided
- Press ON push button on pendent / Remote - The main contactor will gets ON
and the respective Indicating light provided on the Main Panel will glow.
- Now carryout the pre-commissioning tests and functional tests before operating
the crane.
- Before moving the Crane, check no parts /describes kept on the Crane or along
the Bay length.
- Check the current collector fixing and power conductor bar assemblies.
Saudi Cranes & Steel Works
Jubail – K.S.A.

INSTALLATION PROCEDURE

5.0 Typical Erection Plan / Lifting arrangement Clippings :

Saudi Cranes & Steel Works
Jubail – K.S.A.

INSTALLATION PROCEDURE
Saudi Cranes & Steel Works
Jubail – K.S.A.

INSTALLATION PROCEDURE
Saudi Cranes & Steel Works
Jubail – K.S.A.

INSTALLATION PROCEDURE
Saudi Cranes & Steel Works
Jubail – K.S.A.

INSTALLATION PROCEDURE