TCE-4556A-RB1a-IEICO-0004-Crane Motor Power & Brake Calculation (Rev-1)

CALCULATION FOR MOTOR POWER, BRAKE, WIRE ROPE & ROPE SHEAVE
PACKAGE NAME:2 X 125 MW THERMAL POWER PROJECT AT CODE: RB1a

BARSINGSAR, RAJASTHAN
CONSULTANT:TATA CONSULTING CONTRACTOR:INDIA ENGINEERING &
ENGINEERS LIMITED IMPLEMENTS CO.
PROJECT : 10T x18.5 M Span EOT Crane, Workshop Building for Neyveli Lignite
Corporation
LOA No.: COCONTS/0004P/BTTP/RB1a/EOT Crane/Cont.Thermal/2010 dtd 18.04.2011
Ref Drg No: IEI/03/2690 – General Arrangement of 10 x 18.5 M Span DG EOT Crane
I HOIST MECHANISM
A. MOTOR
1. Capacity : 10 Ton
2. Wt. of Hook Block & Rope : 0.3 Ton
3. Mass of Rated Load + Hook Block + Wire Rope (M) : 10.3 Ton
4. Speed (S) : 1.2 Mtr/min
5. Class of Duty : Class M5 (Mechanical), IS: 13834
Class M7 (Electrical), IS: 13834
6. Cv = Service Factor for Vertical motion : 0.67
7. Cdf = Duty Factor : 1.6
8. No. of Rope Fall : 4
9. Ambient Temperature : 50o C.
10. Efficiency of Hoist Mech. (E) : (0.95)4 x 0.99 = 0.8064
11. Temp. Conversion Factor : 0.88
Required Motor Power as per IS: 3177
M x S x Cv x Cdf = 10.3 x 1.2 x 0.67 x 1.6 = 2.69 Kw

6.12 E 6.12 x 0.8064
Motor Power required for 50o C. = 2.69 = 3.06 Kw.

0.88
Motor Selected : 3.7 Kw. 6 Pole (920 r.p.m.) 112M Frame, Crane Duty
Squirrel Cage Motor, S4 Duty, 40% CDF, 150 starts/hour,
Class `F’ Insulation, IP-55 enclosure.
Make: Bharat Bijli
Ratio of Rated Motor Power to Calculated Motor Power = 3.7 / 3.06 = 1.21
Rev: 01
IEICO INDIA ENGG & DOCUMENT NO:
Date:25.07.2011
IMPLEMENTS CO TCE-4556A-RB1a-IEICO-0004
Page 1 of 6
Corporation
B. BRAKE
Required Braking Torque = 960 x 2.69 x 1.5 = 4.21 KgM.

920
Brake Selected : (1) DC Electromagnetic Brake

Size: 160 mm. dia, Rated Torque: 7.6 KgM.
Make: Electromag Method
(2) Electro Hydraulic Thruster Operated Brake
Size: 160 mm. dia, Rated Torque: 9 KgM.
II CROSS TRAVEL MECHANISM
A. MOTOR
1. Weight of Trolley Assembly : 3.7 Ton

2. Mass of Trolley + Rated Load (M) : 13.7 Ton
3. Speed (V) : 15 Mtr/min
4. Acceleration (a) : 8 cm/sec2
5. Factor for permissible motor torque during accn. (T) : 1.7
6. Service Factor (S) : 1.06
7. Duty Factor (Cdf) : 1.4
8. Overall friction factor : 8
9. Mechanical efficiency (N) : (0.95)3 = 0.857
M x V x S x Cdf x F + 1100 x a
6117 x T 981 x N
= 13.7 x 15 x 1.06 x 1.4 x 8 + 1100 x 8

6117 x 1.7 981 x 0.857
= 0.0293 (8 + 10.467) = 0.54 Kw.
Rev: 01
Date:25.07.2011
Page 2 of 6
Corporation

0.88
Motor Selected : 1.1 Kw. 6 Pole (900 r.p.m.) 90S Frame, Crane Duty Squirrel
Cage Motor, S4 Duty, 40% CDF, 150 starts/hour, Class `F’
Insulation, IP-55 enclosure.
Make: Bharat Bijli
B. BRAKE
Required Braking Torque : 960 x 0.54 x 1.25 = 0.72 KgM.

900

III LONG TRAVEL MECHANISM

A. MOTOR
1. Weight of Crane : 13 Ton

2. Mass of Crane + Rated Load (M) : 23 Ton
3. Speed (V) : 30 Mtr/min
4. Acceleration (a) : 11 cm/sec2
5. Factor for permissible motor torque during accn. (T) : 1.7
6. Service Factor (S) : 1
7. Duty Factor (Cdf) : 1.4
8. Overall friction factor : 8
9. Mechanical efficiency (N) : (0.95)2 = 0.9025
Rev: 01
Date:25.07.2011
Page 3 of 6
Corporation
M x V x S x Cdf x F + 1100 x a
6117 x T 981 x N
= 23 x 30 x 1 x 1.4 x 8 + 1100 x 11
6117 x 1.7 981 x 0.9025
= 0.093 x (8 + 13.67) = 2.02 Kw.

0.88
For dual drive, each motor power required = 2 x2.30 = 1.53Kw

3
Motor Selected : 2.2 Kw. 6 Pole ( 930 r.p.m.) 100L Frame, Crane Duty
Squirrel Cage Motor, S4 Duty, 40% CDF, 150 starts/hour,
Class `F’ Insulation, IP-55 enclosure.
Make: Bharat Bijli
B. BRAKE
Calculated power for each motor without considering ambient temperature factor
= 2 x 2.02 / 3 = 1.35 KW
Required Braking Torque : 960 x 1.35 x 1.25 = 1.74 KgM.

930
Rev: 01
Date:25.07.2011
Page 4 of 6
Corporation
IV SELECTION OF WIRE ROPE
1. Capacity : 10 Ton
2. Wt. of Hook Block & Rope : 0.3 Ton
3. Mass of Rated Load + Hook Block + Wire Rope (M) : 10.3 Ton
4. Factor of Safety (S) : 6
5. No of rope falls (N) : 4
Min. required Breaking Strength of Wire Rope = M x S = 10.3 x 6 = 15.45 Ton

N 4
Wire rope selected: 18 mm dia wire rope, 6x36 constructions, Fiber core, Tensile designation of wire –
180 Kgf/mm2, Minm. Breaking Load – 19.2 Ton as per IS: 2266.
V SELECTION OF ROPE DRUM
1. Wire Rope Diameter (d) : 18 mm

2. Duty factor for Hoisting for M5 Class (cdf) : 1.5
3. Factor dependent on the construction of wire rope (Crc) : 1 for 6x36 construction
Dd = Diameter of drum measured at the bottom of the groove = 12 x d x Cdf x Crc

= 12 x 18 x 1.5 x 1 = 324 mm
Rope drum selected: 400 mm PCD rope drum as per IS: 3177.
Rev: 01
Date:25.07.2011
Page 5 of 6
Corporation
VI SELECTION OF ROPE SHEAVES
1. Wire Rope Diameter (d) : 18 mm

2. Duty factor for Hoisting for M5 Class (cdf) : 1.5
3. Factor dependent on the construction of wire rope (Crc) : 1 for 6x36 construction
4. Co-efficient depending upon the type of receiving : 1 for Nb = 1 for drum
system (Crr) = 2 for pulley carrying
the rope in the same
direction of wrap &
Nt = 1 +2 = 3 < 5
Ds = Diameter of rope sheave measured at the bottom of the groove = 12 x d x Cdf x Crc x Crr
= 12 x 18 x 1.5 x 1 x 1 = 324 mm
Rope Sheave selected: 400 mm diameter rope sheave as per IS: 3177.
Equalizing Sheave:
Ds = Diameter of equalizing sheave measured at the bottom of the groove = 8 x d x Cdf x Crc
= 8 x 18 x 1.5 x 1 = 216 mm
Equalizing Sheave selected: 250 mm diameter sheave as per IS: 3177.
Rev: 01
Date:25.07.2011
Page 6 of 6

TCE-4556A-RB1a-IEICO-0004-Crane Motor Power & Brake Calculation (Rev-1)

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TCE-4556A-RB1a-IEICO-0004-Crane Motor Power & Brake Calculation (Rev-1)

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CALCULATION FOR MOTOR POWER, BRAKE, WIRE ROPE & ROPE SHEAVE

PACKAGE NAME:2 X 125 MW THERMAL POWER PROJECT AT CODE: RB1a

Required Motor Power as per IS: 3177

M x S x Cv x Cdf = 10.3 x 1.2 x 0.67 x 1.6 = 2.69 Kw

Motor Power required for 50o C. = 2.69 = 3.06 Kw.

Required Braking Torque = 960 x 2.69 x 1.5 = 4.21 KgM.

Brake Selected : (1) DC Electromagnetic Brake

1. Weight of Trolley Assembly : 3.7 Ton

Required Motor Power as per IS: 3177

= 13.7 x 15 x 1.06 x 1.4 x 8 + 1100 x 8

= 0.0293 (8 + 10.467) = 0.54 Kw.

Motor Power required for 50o C. = 0.54 = 0.61 Kw.

Required Braking Torque : 960 x 0.54 x 1.25 = 0.72 KgM.

Brake Selected : (1) DC Electromagnetic Brake

III LONG TRAVEL MECHANISM

1. Weight of Crane : 13 Ton

Required Motor Power as per IS: 3177

= 0.093 x (8 + 13.67) = 2.02 Kw.

Motor Power required for 50o C. = 2.02 = 2.30 Kw.

For dual drive, each motor power required = 2 x2.30 = 1.53Kw

Required Braking Torque : 960 x 1.35 x 1.25 = 1.74 KgM.

IV SELECTION OF WIRE ROPE

Min. required Breaking Strength of Wire Rope = M x S = 10.3 x 6 = 15.45 Ton

V SELECTION OF ROPE DRUM

1. Wire Rope Diameter (d) : 18 mm

Dd = Diameter of drum measured at the bottom of the groove = 12 x d x Cdf x Crc

VI SELECTION OF ROPE SHEAVES

1. Wire Rope Diameter (d) : 18 mm

Equalizing Sheave selected: 250 mm diameter sheave as per IS: 3177.

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