Approval Return Status:

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N.
This document is the exclusive property of ALSTOM POWER and shall not be used, copied or communicated to third parties without their prior authorization

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Ce document propriété de ALSTOM POWER ne doit pas être utilisé, copié ou communiqué à des tiers sans son autorisation

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Sign.
N. Jay---
Sign. Revised as per NHPC comments dated
B N. JAY B.D.BOSE K.K.PATHAK 17.06.08 GFR
02.06.08
Sign.
A N. JAY B.D.BOSE K.K.PATHAK 31.03.08 FIRST ISSUE GFR
REV.

ESTABLISHE
CHECKED APPROVED DATE MODIFICATIONS STAT.
D

NATIONAL HYDROELECTRIC POWER CORPORATION LIMITED

(A Government of India Enterprise)

CHAMERA-III HYDROELECTRIC PROJECT

3 x 77 MW
LOT III : ELECTRO- MECHANICAL WORKS

CONSORTIUM LEADER
ALSTOM Power Hydraulique ALSTOM Projects India Limited
ALSTOM Projects India Limited


EOT CRANE FOR GIS HALL

DESIGN CALCULATION

SCALE

POWER SYSTEMS

S/S
N. of S
Rev. END
HIN CMR 60 SMQ ED 00 100 AIL/APIL-5 T _968_01
B 30
1/30
 TABLE DES MODIFICATIONS / MODIFICATIONS TABLE

ETABLI VERIFIE APPROUVE

REV DATE MODIFICATIONS STAT.
ESTABLISHED CHECKED APPROVED

A JAY B.D.BOSE K.K.PATHAK 31/03/08 First issue GFR

B JAY B.D.BOSE K.K.PATHAK 17/06/08 Second issue GFR

HIN CMR 60 SMQ ED 00 100 Page 2 of 30

 INDEX

SL. NO. DESCRIPTION PAGE NO.

0 CRANE DATA 4
1 MAIN HOIST MOTOR CALCULATION 5
2 MAIN HOIST BRAKE CALCULATION 6
3 CROSS TRAVEL MOTOR CALCULATION 7
4 CROSS TRAVEL BRAKE CALCULATION 8
5 LONG TRAVEL MOTOR CALCULATION 9
6 LONG TRAVEL BRAKE CALCULATION 10
7 MAIN HOIST WIRE ROPE SELECTION CALCULATIONS : 11-12
8 MAIN HOIST DRUM / SHEAVE SELECTION CALCULATIONS 13-16
9 CROSS TRAVEL MACHINERY CALCULATIONS 17-18
10 LONG TRAVEL MACHINERY CALCULATIONS. 19-20
11 MISC. CALCULATION. 21-30

HIN CMR 60 SMQ ED 00 100 3 of 30

 CRANE DATA

TYPE OF CRANE : DOUBLE GIRDER EOT CRANE

CAPACITY MH : 5 TON
SPAN : 8.5 MTR.
LIFT MH : 11 MTR.

BAY LENGTH : 28.00 MTR.

CLASS : M5
DUTY : INDOOR
DESIGN STANDRD : IS 3177 -1999 & IS 807/800
AMBIENT TEMP. : 40 Deg. C
DSL TYPE : Shrouded Type.
SPEED (M/MIN) MAIN MICRO
MH : 2 5 to 100 % Through VVVF Drive.
CT : 10 5 to 100 % Through VVVF Drive.
LT : 15 5 to 100 % Through VVVF Drive.

MH NO. OF FALLS : 4
CRANE WEIGHT : 11 TON
CRAB WEIGHT : 2 TON

HIN CMR 60 SMQ ED 00 100 4 of 30

 1. MAIN HOIST MOTOR SELECTION :-

Hoisting Power Required P = (Q + q+r) x V x Cv X Cdf x MF X 1

6120 x E C amb

Q= Load to be lifted in kg 5000

q = Weight of Bottom Pulley Block in kg+Hook Wt 150
r= Weight of wire rope in kg, (0.602 KG/M X 62 M-Rope length) 37
V = Main Hoisting Speed in m/min 2
MF = Multification factor for motor qty. 1
Cv = Service Factor 0.67
E= Combined Efficiency for Gears & Sheaves
(0.95)n x (0.99)m
n= Nos .of Pairs of Gears. 3
m= Total number of Rotating Sheaves 1
Passed over by each part of the
moving rope attached to the drum
E= Combined Efficiency for Gears & Sheaves 0.8488
Cdf = Duty Factor as per Class M5 1.5
Camb= Ambient Temperature derating factor for 40° c 1

Motor KW Rating Required P = 2.01 KW

HENCE MOTOR SELECTED :

TYPE OF MOTOR SQ MOTOR

FRAME SIZE VD132MA
KW RATING 3.50

MAKE ALSTOM
NO. OF POLES OF MOTOR 6
CDF OF MOTOR 40%
RPM OF MOTOR 960
ST/HR OF MOTOR 150
QTY. OF MOTOR 1
INSULATION CLASS - F
ENCLOSURE TEFC
PROTECTION IP-55

HIN CMR 60 SMQ ED 00 100 5 of 30

 2. MAIN HOIST BRAKE CALCULATION :

Braking Torque Required = 975 x Motor KW x Service Factor

Motor RPM
Where
Service Factor = (As per IS 3177-1999 Clno. 8.12.3) 1.5
Motor KW = 2.01
Motor RPM = 960

Therefore Braking Torque Required = 3.06 kg-m

BRAKE SELECTED :-

Type of Brake EHT

Drum dia. , mm 160
Torque Rating , kg-m 9.00
Thrustor capacity kg 18.00
Make SOC
Qty. 1

Type of Brake DCEM

Drum dia. , mm 160
Torque Rating , kg-m B 8.00
Make SOC
Qty. 1

HIN CMR 60 SMQ ED 00 100 6 of 30

 3. C.T. MOTOR CALCULATION :

KW REQUIRED = M * V * Cdf *S * ( F + 1100 * a ) * MF X 1

6117 * T 981 * E C amb
Where,
M= MASS MOVED IN TONNES
= WT. OF TROLLEY + LIFTED CAPACITY = 7
V= SPECIFIED FREE RUNNING SPEED IN m/min = 10
MF = MULTIPLICATION FACTOR FOR MOTOR QTY 1.00
Cdf= For Class M5 1.25
S= Service Factor for CT 1.06
T= TORQUE FACTOR = 1.7
F= FRICTIONAL RESISTANCE(Antifriction Bearing) , kgf/t = 8.00
a= AVERAGE ACCELERATION OF CRANE IN cm/sq sec. 8
Revised As per IS-3177(1999), Upto 15M/Min
n= No. of Stage of Gear box 2
E= MECHANICAL EFFICIENCY OF GEARING
= (0. 95)n 0.903
(0. 95 PER STAGE OF GEARBOX)
Camb= Ambient Temperature derating factor for 40° c 1

Motor KW Rating Required P= 0.16 KW

HENCE MOTOR SELECTED :

TYPE OF MOTOR SQ MOTOR

FRAME SIZE VD80
KW RATING 0.50

MAKE ALSTOM
NO. OF POLES OF MOTOR 6
CDF OF MOTOR 40%
RPM OF MOTOR 960
NO. OF ST./HR 150
Qty. OF Motor 1
INSULATION CLASS-F
ENCLOSURE TEFC
PROTECTION IP-55

HIN CMR 60 SMQ ED 00 100 7 of 30

 4. BRAKE CALCULATIONS FOR CT :

Braking Torque Required = 975 x Motor KW x Service Factor

Motor RPM
Motor KW = 0.16
MOTOR RPM= 960
Service Factor= 1.5
Therefore,
BRAKING TORQUE REQUIRED IN kg.m = 0.24

HENCE WE HAVE SELECTED FOLLOWING BRAKE :

Type of Brake EHT

Drum dia. , mm 160
Torque Rating , kg-m 9
Thrustor capacity kg 18
Make SOC
Qty. 1

Type of Brake DCEM

Drum dia. , mm 160
Torque Rating , kg-m B 8.00
Make SOC
Qty. 1

HIN CMR 60 SMQ ED 00 100 8 of 30

 5. LT MOTOR CALCULATION :

KW REQUIRED = M * V * Cdf *S * ( F + 1100 * a ) * MF X 1

6117 * T 981 * E C amb
Where,
M= MASS MOVED IN TONNES
= WT. OF CRANE + LIFTED CAPACITY = 16
V= SPECIFIED FREE RUNNING SPEED IN m/min = 15
MF = MULTIPLICATION FACTOR FOR MOTOR QTY 0.60
Cdf= For Class M5 1.25
S= Service Factor= 1.00
T= TORQUE FACTOR = 1.7
F= FRICTIONAL RESISTANCE(Antifriction Bearing) , kgf/t = 8.00
a= AVERAGE ACCELERATION OF CRANE IN cm/sq sec. 15

n= No. of Stage of Gear box 2

E= MECHANICAL EFFICIENCY OF GEARING
n
= (0.95) 0.903
(0.95 PER STAGE OF GEARBOX)
Camb= Ambient Temperature derating factor for 40° c 1

Motor KW Rating Required P = 0.46 KW

HENCE MOTOR SELECTED :

TYPE OF MOTOR SQ MOTOR

FRAME SIZE VD90S
KW RATING 0.60

MAKE ALSTOM
NO. OF POLES OF MOTOR 6
CDF OF MOTOR 40%
RPM OF MOTOR 960
NO. OF ST./HR 150
Qty. OF Motor 2
INSULATION CLASS-F
ENCLOSURE TEFC
PROTECTION IP-55

HIN CMR 60 SMQ ED 00 100 9 of 30

 6. BRAKE CALCULATIONS FOR LT :

Braking Torque Required = 975 x Motor KW x Service Factor

Motor RPM
Motor KW = 0.46
MOTOR RPM= 960
Service Factor= 1.5

Therefore,
BRAKING TORQUE REQUIRED IN kg.m = 0.70

HENCE WE HAVE SELECTED FOLLOWING BRAKE :

Type of Brake EHT

Drum dia. , mm 160
Torque Rating , kg-m 9
Thrustor capacity kg 18
Make SOC
Qty. 1+1

Type of Brake DCEM

Drum dia. , mm 160
Torque Rating , kg-m B 8.00
Make SOC
Qty. 1+1

- FOOT OPERATED BRAKE.

Rated Full Load Torque Of Motor In Kg-m = 0.60

Therefore,
BRAKING TORQUE REQUIRED IN kg.m = 0.60 x1.5 = 0.91

Type of Brake EHT

Drum dia. , mm 160
Torque Rating , kg-m 9
Thrustor capacity kg 18
Qty. 1+1

HIN CMR 60 SMQ ED 00 100 10 of 30

 7. MAIN HOIST WIRE ROPE SELECTION CALCULATIONS

THE MINIMUM BREAKING LOAD OF THE WIRE ROPE = ( Q + Wsb ) x Zp x Cdf

N X COS 5°

Where,
Q= LIFTED LOAD IN TON 5
Wsb = WEIGHT OF SNATCH BLOCK IN TON + WIRE ROPE WEIGHT 0.19
N= NUMBER OF FALLS 4
Zp= CO-EFFICIEINT OF UTILISATION FOR CLASS M5. 3.5
Cdf= DUTY FACTOR FOR VERTICAL MOTION FOR CLASS M5 1.5
MAX ALLOWABLE FLEET ANGLE 5°
MINIMUM BREAKING LOAD OF WIRE ROPE REQUIRED (Ton) = 6.8
67.1 KN

SELECTED ROPE:

DIA(mm) 12
CONSTRUCTION 6X36
CORE STEEL CORE ,
QUALITY 1960 N/mm^2
BREAKING STRENGTH 101 KN
MAKE USHA MARTIN
0.602
61.6

ACTUAL F.O.S = ACTUAL BRAKING STRENGTH

REQUIRED BRAKING STRENGTH
Where,
ACTUAL BRAKING STRENGTH 101 KN
REQUIRED BRAKING STRENGTH ( (Q+Wsb) / ( N X COS 5°) ) 12.77 KN
7.91
ACTUAL F.O.S = 7.91 > 6

HIN CMR 60 SMQ ED 00 100 11 of 30

 CHECKING WIRE ROPE UNDER BREAKDOWN / PULL OUT TORQUE.

Motor Rated Power = 3.50 KW

Motor Pullout Torque Factor= 2.5
Motor Full Load Torque= (974 X 3.5) / 960 3.55 Kg. M
Motor Breakdown Torque =3.552 * 2.5 8.88 Kg. M
Gearbox Rated Ratio= 317.28 :1
Gearbox Output Torque = 317.28 * 8.88 2816.69 Kg. M
Rope Drum PCD = 400- (12 x 0.35X2) + 12 404 mm
Rope Tension= 2816.69 / (2 x404 /2 ) = = 6.97 T
= 64.00 KN

Rope Tension 64.01 KN < Rope Braking Strength 101 KN , Hence OK

HIN CMR 60 SMQ ED 00 100 12 of 30

 8. MAIN HOIST DRUM SELECTION CALCULATIONS

Minimum Drum Diameter. = 12*d*Cdf*Crc

Cdf= 1.5 Rope Dia= 12 mm
Where Crc= 1
Minimum Drum Diameter . Required 216.00
Hence,
SELECTED DRUM DIAMETER = 400

MAIN HOIST SHEAVE SELECTION CALCULATIONS

Minimum Sheave Diameter. = 12*d*Cdf*Crc*Crr

Where Crr= 1
Minimum Sheave Diameter . Required 216.00
Hence,
SELECTED SHEAVE DIAMETER = 320

Min Equiliser Sheave Diameter. =8*d*Cdf*Crc 144.00

SELECTED EQUILISER SHEAVE DIAMETER = 160

DRUM LENGTH CALCULATION

NO. OF ACTIVE GROOVE REQUIRED ON EACH SIDE = LIFT * FALLS

2 * ( 3.14 * P.C.D )
WHERE ,
LIFT = HEIGHT OF LIFT IN MTR = 11.00
FALLS = NO. OF FALLS = 4
P.C.D = PITCH CIRCLE DIA. OF ROPE DRUM IN MTR = 0.404

THEREFORE,
NO. OF ACTIVE GROOVE REQUIRED ON EACH SIDE = 17
NO OF SPARE GROOVE ON EACH SIDE = 5
TOTAL NO. OF GROOVE ON EACH SIDE = 22

HIN CMR 60 SMQ ED 00 100 13 of 30

 LENGTH OF EACH ROPE DRUM = 2 * NO OF GROOVE ON EACH SIDE * PITCH/ QTY
+ ULC + 2* ULE
WHERE
PITCH = PITCH OF GROOVE IN MM = 14.00
ULC = UNGROOVED LENGTH AT CENTRE IN MM 175
ULE = UNGROOVED LENGTH & FLANGE THICKNESS AT END IN MM 75
QTY = QTY OF ROPE DRUM 1

THEREFORE ,
LENGTH OF EACH ROPE DRUM IN MM = 941
SELECTED LENGTH OF EACH ROPE DRUM IN MM = 941

MINIMUM DRUM THICKNESS BELOW REQUIRED = MAX. LOAD ON WIRE ROPE

PITCH * ALL. CRUSHING STRESS
WHERE ,
MAXIMUM LOAD ON WIRE ROPE IN KG = 1302
ALL. CRUSHING STRESS OF ROPE DRUM IN KG/MM^2 = 8.56
THEREFORE,
t1= MINIMUM DRUM THICKNESS BELOW GROOVE IN MM = 12.74
DEPTH OF DRUM GROOVE IN MM (ROPE DIA. X 0.35) = 4.2
MACHINING ALLOWANCE OF DRUM IN MM = 3.0
THEREFORE,
MINIMUM THICKNESS OF DRUM REQUIRED , MM = 19.94
SELECTED THICKNESS OF DRUM REQUIRED , MM = 20

HENCE FOLLOWING SPECIFICATIONS OF DRUM AND SHEAVE ARE SELECTED :

ROPE DRUM Rope Drum Diameter., mm 400

Ungrooved length at Centre, mm 175
Ungrooved length at End with Flange, mm 75
Pitch , mm 14
Length , mm 941
Drum Thickness, mm 20
Qty 1
SHEAVE Sheave Diameter, mm 320
Qty 2
EQUALISING SHEAVE
Sheave Diameter, mm 160
Qty 1

HIN CMR 60 SMQ ED 00 100 14 of 30

 1.302 1.302 T 0.160 (T/mtr UDL)

383 175 383

1.38 T 941 1.38 T

Maximum Load On Wire Rope I Kg (Load / Fall) = = 1302 Kg

Thickness Below groove in (t1) = = 12.7 mm
Pitch of Groove in = = 14 mm
PCD of Rope drum= = 400- (12 x 0.35X2) + 12 = 404 mm
Groove Depth (dg = 0.35 x Rope Dia) = = 4.2 mm
Drum Diameter Bottom Of Groove (D1) = = 391.6 mm
Inside Diameter of Drum (D2) = = 366.1 mm
Self Weight of Rope Drum = = 0.160 T/mtr
= 0.151 T

a). fc = Crushing Stress = Load / Fall kgf/cm² = 730.00 Kgf/cm²

Pitch x (t1)

b). fb= Compression Stress Due to Bending. = B.M = 0.037 T/cm²

Zxx = 37.10 kgf/cm²

Section Modulas of Drum = Zxx = 3.14 x (D1ˆ 4 - D2ˆ4) = 1390.23 cm³

32 x D1

Maximum Bending Moment = B.M =(1.38x( 38.3))-((0.16x(38.3)x(38.3))/((94.1)x2)) = 51.57 T-cm

c). Shear Stress Due TO Torsion. (fTs) = C / Zp = = 18.92 kgf/cm²

Since There are two Fall From Drum =

Torsion On Drum = C = 2 x1301.91 x ( 40.4/2) = 52597.10 Kgf-cm

Zp = Torsional Section Modulas = 3.14 x (D1ˆ 4 - D2ˆ4) = 2780.47 cm²

16 x D1

d). Combine Stress (feq) = (fb+fc)² + (3 x fTs²) = 767.80 kgf/cm²

e). Allowable Combined Stress = Fy1 x 100 / (9.81/5) = 846.08 kgf/cm²

Fy1= Material UTS. = 415 Mpa

Hence, Actual Combine Stress 767.8 kgf/cm² < 846.08 kgf/cm² Allowable Combine Stress.

HIN CMR 60 SMQ ED 00 100 15 of 30

 MAIN HOIST GEARBOX RATIO

GEAR RATIO REQUIRED = ( 3.1416 * PCD * RPM )

V * N/2
Where,
PCD = PITCH CIRCLE DIAMETER OF THE ROPE DRUM IN M 0.404
RPM = MOTOR RPM 960
V= HOIST SPEED IN M/MIN 2
N= NUMBER OF FALLS 4
THEREFORE,
GEAR RATIO REQUIRED = 304.61 :1
QTY = 1
HENCE GEAR BOX SELECTED RATIO: 317.28 :1
SIZE 3AH475

B Actual Speed, m/min. = 3.1416 * PCD * MOTOR RPM

GEAR RATIO * N/2

= 1.93 m/min..

Percentage in Speed variation = Required Speed - Actual Speed

Required Speed
= 3.5 %

HIN CMR 60 SMQ ED 00 100 16 of 30

 Hook Centre

9. C.T. MACHINERY CALCULATION:

C.T WHEEL SIZING CALCULATIONS 560 940
1500
MAX. WHEEL LOAD ON C.T WHEEL = K1 * (SWL+CRAB WT)
NO. OF CT WHEELS /2
WHERE ,
SWL = SAFE WORKING LOAD OF MAIN HOIST IN TONS = 5
CRAB WT. IN TONS = = 2
NO. OT CT WHEELS = = 4
K1 = % OF LOAD DISTRIBUTED ON ONE SIDE OF CRAB = 0.63
B = 940 / 1500 = 63 % (as per indicated diagram)
MAX. WHEEL LOAD ON C.T WHEEL = 2.21 TONS
= 2205 KG

MIN. WHEEL LOAD ON C.T WHEEL = K2 * CRAB WT

NO. OF CT WHEELS /2
B K2 = % OF LOAD DISTRIBUTED ON ONE SIDE OF CRAB = 0.37
= 540 / 1500 = 37 %
MIN. WHEEL LOAD ON C.T WHEEL = 0.37 TONS

MEAN WHEEL LOAD IN TONS = 2 X Pmax +Pmin

3
MEAN WHEEL LOAD IN TONS = 1.59 TONS

MINIMUM WHEELTREAD DIA. REQUIRED = W X Cdf X Csf

1.5 X a X Cbh X Csp
WHERE,
W= MEAN WHEEL LOAD IN NEWTONS = 15631
Cdf= DUTY FACTOR FOR HORIZONTAL MOTION FOR CLASS M5 = 1.25
SELECTED CT RAIL SIZE 30 lbs/yard
a= USEFUL RAIL TOP WIDTH(MM) = 33.2
Csf= SAFETY FACTOR FOR WHEEL MATERIAL USED = 1.25

Cbh= HARDNESS FACTOR FOR WHEEL MATERIAL AS PER IS 3177-1999 = 7.35

for 19.90 RPM as
Csp= CO-EFFICIENT DEPENDING ON SPEED OF ROTATION OF WHEEL = 1.06 per IS

HENCE,
MINIMUM WHEEL TREAD DIA REQUIRED (MM) 63
SELECTED WHEEL TREAD DIAMETER (MM) 160

HIN CMR 60 SMQ ED 00 100 17 of 30

 CT GEARING
DRIVE : Central
GEAR RATIO REQUIRED = 3.1416 * WHEEL DIA * RPM =
V * 1000
Where,
MOTOR RPM = 960
WHEEL DIAMETER IN mm = 160
V= C.T SPEED IN M/MIN = 10
Therefore GEAR RATIO REQUIRED = 48.25 :1

HENCE GEAR BOX SELECTED RATIO: 48.57 :1

QTY 1
SIZE VR300

Actual Speed, m/min. = 3.1416 * WHEEL DIA. * MOTOR RPM

B GEAR RATIO * 1000

= 9.94 m/min..

Percentage in Speed variation = Required Speed - Actual Speed

Required Speed
= 0.601 %

HIN CMR 60 SMQ ED 00 100 18 of 30

 10. L.T. MACHINERY CALCULATION:
L.T WHEEL SIZING CALCULATIONS

MAX. WHEEL LOAD = (S-A)*(CRAB WT. + SWL) + (CRANE WT - CRAB WT )

ON L.T WHEEL S * NO. OF LT WHEELS /2 NO. OF LT WHEELS
WHERE ,
S= SPAN IN MTR = 8.5
A= MIN. HOOK APPROACH IN MTR = 0.7
SWL = SAFE WORKING LOAD OF MAIN HOIST IN TONS = 5
CRAB WT. IN TONS = 2
CRANE WT. IN TONS = 11
NO. OT LT WHEELS = 4
THEREFORE,
MAX. WHEEL LOAD ON L.T WHEEL = IN TONS 5.462

MIN. WHEEL LOAD = (A)*(CRAB WT. + SWL) + (CRANE WT - CRAB WT )

ON L.T WHEEL S * NO. OF LT WHEELS /2 NO. OF LT WHEELS

THEREFORE,
MIN. WHEEL LOAD ON L.T WHEEL = IN TONS 2.538

MEAN WHEEL LOAD IN TONS = 2 X Pmax +Pmin

3
MEAN WHEEL LOAD IN TONS = 4.487

MINIMUM TREAD DIA. REQUIRED = W X Cdf X Csf

1.5 X a X Cbh X Csp
WHERE,
W = MEAN WHEEL LOAD IN NEWTONS = 44020
Cdf= DUTY FACTOR FOR HORIZONTAL MOTION FOR CLASS M5 = 1.25
SELECTED CT RAIL SIZE = 30 lbs/yard
a= USEFUL RAIL TOP WIDTH(MM) = 33.2
Csf= SAFETY FACTOR FOR WHEEL MATERIAL USED = 1.25
Cbh= HARDNESS FACTOR FOR WHEEL MATERIAL AS PER IS 3177-1999 7.35

for23.88 RPM as
Csp= CO-EFFICIENT DEPENDING ON SPEED OF ROTATION OF WHEEL = 1.11 per IS

HENCE,
MINIMUM WHEEL TREAD DIA REQUIRED (MM) 169.3
SELECTED WHEEL TREAD DIAMETER (MM) 200

HIN CMR 60 SMQ ED 00 100 19 of 30

 LT GEARING
DRIVE : Twin
GEAR RATIO REQUIRED = 3.1416 * WHEEL DIA * RPM =
V * 1000
Where, MOTOR RPM = 960
WHEEL DIAMETER IN mm = 200
V= L.T SPEED IN M/MIN = 15
Therefore GEAR RATIO REQUIRED = 40.21 :1

HENCE GEAR BOX SELECTED RATIO: 40.17 :1

QTY 2
SIZE VR300

Actual Speed, m/min. = 3.1416 * WHEEL DIA. * MOTOR RPM

B GEAR RATIO * 1000

= 15.02 m/min..

Percentage in Speed variation = Actual Speed - Required Speed

Actual Speed
= 0.134 %

HIN CMR 60 SMQ ED 00 100 20 of 30

 11. MISC. CALCULATION FOR 5 TON DG EOT CRANE
Page No
1. LONG TRAVEL WHEEL AXLE CALCULATION: 22
2. CROSS TRAVEL WHEEL AXLE CALCULATION: 23
3. BEARING SELECTION FOR LT & CT DRIVE: 24
4. COUPLING CALCULATION FOR LONG TRAVEL OUTPUT 25
5. MAIN HOIST ROPE DRUM STUB SHAFT AND BEARINGS SELECTION 26
6. CALCULATION OF SPRING BUFFER FOR LT & CT 27
7. LT WHEEL AND RAIL SELECTION 28
8. CT WHEEL AND RAIL SELECTION 29
9. LT FLOTING SHAFT CALCULATION 30
10. CT FLOTING SHAFT CALCULATION 30

HIN CMR 60 SMQ ED 00 100 21 of 30

 (1) LONG TRAVEL WHEEL AXLE CALCULATION:

5.462

58 mm(Dia)

200mm 230mm

100 mm

19 cm

-- W-MAX WHEEL LOAD = 5462 Kg

-- L = 19 Cm
-- V = 15 M/MIN
-- MAXIXMUM BENDING MOMENT AT X-X = Mxx =(W X L/4) - (W X L/8) = 12972 Kg-Cm
=(5462*19/4)-((5462*19/8))

-- OUT PUT RPM = V = 23.885 R.P.M

3.14* D
-- OUT PUT TORQUE = T = 974X 0.6 = 24.47 Kg-M = 2447 Kg-Cm
R.P.M
-- COMBINE TWISTING MOMENT Te = M² + T² = 13200 Kg-Cm
-- COMBINED BENDING MOMENT Me = 0.5 ( M+ M² + T² ) = 13086 Kg-Cm

-- HENCE ACTUAL COMBINED TWISTING STRESS = fs = (Te X 16) / (3.14Xd³)= 345 Kg/Cm²
-- HENCE ACTUAL COMBINED BENDING STRESS = fb = (Me X 32) / (3.14Xd³)= 684 Kg/Cm²
-- d = DIAMETER OF AXEL = 58 mm

-- AXEL MATERIAL : En8 , YIELD STRESS = 2800 Kg/Cm², UTS = 5500 Kg/Cm²

-- ALLOWABLE BENDING STRESS = fb = 0.2 UTS or 0.5 Ys (WHICHEVER IS LESS.)

= 0.2 X 5500 or 0.5 X 2800
=1100 Kg/Cm² or 1400 Kg/Cm²

-- ALLOWABLE SHEAR STRESS = fsp = 0.3 Ys

= 0.3 X 2800
= 840 Kg/Cm²

SO WE FIND, fb = 684 Kg/Cm² < 1100 Kg/Cm². & fs = 345 < 840 Kg/Cm².

HIN CMR 60 SMM ED 00 100 22 of 30

 (2) CROSS TRAVEL WHEEL AXLE CALCULATION:

2.1 T

50mm(Dia)

160 mm 190mm

x
85mm

17 cm

-- W-MAX WHEEL LOAD= 2205 Kg

-- L = 17 Cm
-- V = 10 M/MIN
-- MAXIXMUM BENDING MOMENT AT X-X = Mxx =(W X L/4) - (W X L/8) = 4686 Kg-Cm
-- =(2205*17/4)-((2205*17/8))

-- OUT PUT RPM = V = 19.90 R.P.M

3.14* D
-- OUT PUT TORQUE = T = 974X 0.5 = 24.47 Kg-M = 2447 Kg-Cm
R.P.M
-- COMBINED TWISTING MOMENT Te = M² + T² = 5286 Kg-Cm
-- COMBINED BENDING MOMENT Me = 0.5 ( M+ M² + T ) = 4986 Kg-Cm

-- HENCE ACTUAL COMBINED TWISTING STRESS =fs= (Te X 16) / (3.14Xd³)= 215 Kg/Cm²
-- HENCE ACTUAL COMBINED BENDING STRESS =fb = (Me X 32) / (3.14Xd³)= 406 Kg/Cm²
-- d = DIAMETER OF AXEL = 50 mm

-- AXEL MATERIAL : En8 , YIELD STRESS = 2800 Kg/Cm², UTS = 5500 Kg/Cm²

-- ALLOWABLE BENDING STRESS = fb = 0.2 UTS or 0.5 Ys (WHICHEVER IS LESS.)

= 0.2 X 5500 or 0.5 X 2800
=1100 Kg/Cm² or 1400 Kg/Cm²

-- ALLOWABLE SHEAR STRESS = fsp = 0.3 Ys

= 0.3 X 2800
= 840 Kg/Cm²

SO WE FIND, fb = 406 Kg/Cm² < 1100 Kg/Cm². & fs = 215 < 840 Kg/Cm².

HIN CMR 60 SMM ED 00 100 23 of 30

 (3) BEARING SELECTION FOR LT & CT DRIVE:

) LT DRIVE :

-- BEARING NUMBER = 22210

-- Cr = DYNAMIC CAPACITY = 105 KN
-- Co = STATIC CAPACITY = 124 KN
-- P = TOTAL WHEEL LOAD = 5462 Kg
-- LOAD ON EACH BEARING = 2731 Kg = 26.79 KN

-- fsb = STATIC LOAD = P X Cdf = 26.85X 1.5= 40.2 KN

-- fsb = 40.3< 124 KN
-- HENCE, IT IS Ok.

-- Cr/P = 105/26.85 = 3.92

-- OUT PUT RPM = V = 23.89
3.14 X D
-- V = 15 M/min, D = 200mm
-- OUT PUT RPM (n) = 23.89

-- LIFE IN Hr (C/P)^(10/3) X 10^6 = 65937 > 10000 Hr

60 X n

) CT DRIVE :

-- BEARING NUMBER = 22208

-- Cr = DYNAMIC CAPACITY = 93.1 KN
-- Co = STATIC CAPACITY = 105 KN
-- P = TOTAL WHEEL LOAD = 2205 Kg
-- LOAD ON EACH BEARING = 1103 Kg = 10.82 KN

-- fsb = STATIC LOAD = P X Cdf = 10.30 X 1.5= 16.2

-- fsb = 15.5 < 105 KN
-- HENCE, IT IS Ok.

-- Cr/P = 93.1 / 10.30 = 8.61

-- OUT PUT RPM = V = 19.90
3.14 X D
-- V = 10 M/min, D = 160mm
-- OUT PUT RPM (n) = 19.90

-- LIFE IN Hr (C/P)^(10/3) X 10^6 = 1086732 > 10000 Hr

60 X n

HIN CMR 60 SMM ED 00 100 24 of 30

 (4) COUPLING CALCULATION FOR LONG TRAVEL OUTPUT

(a) CALCULATION FOR LT:

H.P PER 100 RPM = = HP * Service factor * 100

RPM
Where
SERVICE FACTOR FOR LT = 1.5
MECHANICAL HP = 0.62
OUTPUT RPM= 23.885
Therefore,
H p / 100 RPM = 3.87

HENCE WE HAVE SELECTED FOLLOWING COUPLING :

TYPE OF COUPLING HGC

G.C.NO 101
HP CAPACITY AT 100 RPM 14.00
MAKE NUTECK

b. CALCULATION FOR CT:

H.P PER 100 RPM = = HP * Service factor * 100

RPM
Where
SERVICE FACTOR FOR CT = 1.5
MECHANICAL HP = 0.21
OUTPUT RPM= 19.90
Therefore,
H p / 100 RPM = 1.62

HENCE WE HAVE SELECTED FOLLOWING COUPLING :

TYPE OF COUPLING HGC

G.C.NO 101
HP CAPACITY AT 100 RPM 14.00
MAKE NUTECK

HIN CMR 60 SMM ED 00 100 25 of 30

 (5)MAIN HOIST ROPE DRUM STUB SHAFT AND BEARINGS SELECTION

521 530
1.29 TON
0.278 TON
50 75

Y X
60 70
Y X
B 175
941

1051

- CAPACITY = 5 T

- LOAD / FALL = 5 / (4 X0.99X0.98) = 1.29 T

- ROPE DRUM WEIGHT = 0.278 T

- ROPE DRUM R.P.M = 2/ 3.14 X 0.400 = 0.255 R.P.M

- NOW RB =((1.29*(1051-75-50))/1051)+(0.278*530)/1051) = 1.28 T

- BEARINGS SIZE 22212 (60X110X28),

C= 140 KN 2205 (C/P) = 11.19

Co= 174 KN

- SO, LIFE IN HOURS=((11.19)^3.33*1000000)/(0.255*60) = 2.03E+08 hr >10000 hr

- BENDING MOMENT AT X-X

M xx = 1.28*(50/10) = 6.38 T-Cm

- BENDING STRESS = 6.4 X 10^3 = 189.46 Kg/Cm²

3.14/32 X 7³

- SHEAR STRESS AT Y-Y

fs = 1.28 X 10^3 = 45.13 Kg/Cm²

3.14/4 X 6²

- MATERIAL FOR STUB SHAFT En8 UTS-5500 Kg/Cm² Ys-2800 Kg/Cm²

- ALLOWABLE BENDING STRESS = fb = 0.2 UTS or 0.5 Ys (WHICHEVER IS LESS.)

= 0.2 X 5500 or 0.5 X 2800
=1100 Kg/Cm² or 1400 Kg/Cm²

- ALLOWABLE SHEAR STRESS = fsp = 0.3 Ys

= 0.3 X 2800
= 840 Kg/Cm²

- SO WE FIND, fb = 189.46 Kg/Cm² < 1100 Kg/Cm². & fs = 45.13 < 840 Kg/Cm².

HIN CMR 60 SMM ED 00 100 26 of 30

 (6)CALCULATION OF SPRING BUFFER FOR LT & CT

A CROSS TRAVEL (Traverse)

Total weight of trolley + SWL= 7000 Kg.

Rated Speed = 10 M/min
Design Speed = 5 M/min
(50 % of Rated Speed)

Hence Kinetic energy to be absorbed.

K.E = mv²
2
= 2.5 Kg-m

This kinetic energy is absorbed by two buffer on each side, Hence buffer is selected for

Kinetic Energy P = 2.5

2

P = 1.24 Kg-m

There Fore
Force on each Buffer = P = 22.52 Kg
compression Distance in Mtr

Where, compression Distance = 55 mm

Hence We have selected RSB-1 Buffer with 1500 Kg-Cm > 124 Kg-Cm

B LONG TRAVEL (Travelling)

Total weight of Crane + SWL = 16000 Kg.

Rated Speed = 15 M/min
Design Speed = 7.5 M/min
(50 % of Rated Speed)

Hence Kinetic energy to be absorbed.

K.E = mv²
2
= 12.7 Kg-m

This kinetic energy is absorbed by two buffer on each side, Hence buffer is selected for

Kinetic Energy P = 12.74

2

P = 6.37 Kg-m

There Fore
Force on each Buffer = P = 115.84 Kg
compression Distance in Mtr

Where, compression Distance = 55 mm

Hence We have selected RSB- 1 Buffer with 1500 Kg-Cm > 637 Kg-Cm

HIN CMR 60 SMM ED 00 100 27 of 30

 (7)LT WHEEL AND RAIL SELECTION

MINIMUM TREAD DIA 5.462 = W X Cdf X Csf

1.5 X a X Cbh X Csp
WHERE,
W = MEAN WHEEL LOAD IN NEWTONS = 44020
Cdf= DUTY FACTOR FOR HORIZONTAL MOTION FOR CLASS M5 = 1.25
SELECTED CT RAIL SIZE = 30 lbs/yard
a= USEFUL RAIL TOP WIDTH(MM) = 33.2
Csf= SAFTY FACTOR FOR WHEEL MATERIAL USED = 1.25
Cbh= HARDNESS FACTOR FOR WHEEL MATERIAL AS PER IS 3177-1999 = 7.35
Csp= CO-EFFICIENT DEPENDING ON SPEED OF ROTATION OF WHEEL = 1.11 for23.88 RPM as per IS

a= B - 4r
3
Where,
B= Total Width of Rail = 41.28 As per IS 3443
r= Corner radious of Rail = 6 As per IS 3443

BHw= 1.3 X Bhr X CL

Cz X Cd

BHr= 200 As per Rail IS -3443

CL= 1.14 As per IS-3177(1999)
Cz= 1 As per IS-3177(1999)
Cd= 1.03 As per IS-3177(1999)
BHw= 288 5461.765

AS PER WHEEL HARDNESS BHw= 300 Cbh= 7.35

HENCE,
MINIMUM WHEEL TREAD DIA REQUIRED (MM) = 169.3
SELECTED WHEEL TREAD DIAMETER (MM) = 200

HIN CMR 60 SMM ED 00 100 28 of 30

 (8) CT WHEEL AND RAIL SELECTION

MINIMUM TREAD DIA. REQUIRED = W X Cdf X Csf

1.5 X a X Cbh X Csp
WHERE,
W = MEAN WHEEL LOAD IN NEWTONS = 15631
Cdf= DUTY FACTOR FOR HORIZONTAL MOTION FOR CLASS M3 = 1.25
SELECTED CT RAIL SIZE = 30 lbs/yard
a= USEFUL RAIL TOP WIDTH(MM) = 33.2
Csf= SAFTY FACTOR FOR WHEEL MATERIAL USED = 1.25
Cbh= HARDNESS FACTOR FOR WHEEL MATERIAL AS PER IS 3177-1999 = 7.35
Csp= CO-EFFICIENT DEPENDING ON SPEED OF ROTATION OF WHEEL = 1.06 for 6.37 RPM as per IS

a= B - 4r
3
Where,
B= Total Width of Rail = 41.28 As per IS 3443
r= Corner radious of Rail = 6 As per IS 3443

BHw= 1.3 X Bhr X CL

Cz X Cd

BHr= 200 As per Rail IS -3443

CL= 1 As per IS-3177(1999)
Cz= 1 As per IS-3177(1999)
Cd= 1 As per IS-3 2205
BHw= 260

AS PER WHEEL HARDNESS BHw= 300 Cbh= 7.35

HENCE,
MINIMUM WHEEL TREAD DIA REQUIRED (MM) = 63
SELECTED WHEEL TREAD DIAMETER (MM) = 160

HIN CMR 60 SMM ED 00 100 29 of 30

 (9) LT FLOTING SHAFT CALCULATION
.
WHEEL DIA = 200 MM
WHEEL RPM (N) = 19.1 RPM
POWER REQUIRED IN KW = 0.46 kw

NOW REQUIRED TORQUE =

T= P X 60 = 230.5 N-M
2 X 3.14 X N
= 2511.3 Kg-Cm

FURTHER TORQUE T= 3.14 X fs X d³

16
WHERE
d= SHAFT DIA
fs= ALLOWABLE SHEAR STRESS = 0.3 X Ys = 840 Kg/Cm²

(MATERIAL FOR STUB SHAFT En8 UTS-5500 Kg/Cm² Ys-2800 Kg/Cm²)

d= 24.79 MM

SELECTED DIA OF SHAFT 50 MM > 24.79 MM

NOW SHEAR STRESS FOR 50 MM SHAFT

T= 3.14 X fs X d³ fs= 102 Kg/Cm²< 840 Kg/Cm²

16

(10) CT FLOTING SHAFT CALCULATION

WHEEL DIA = 160 MM

WHEEL RPM (N) = 19.90 RPM
POWER REQUIRED IN KW = 0.16

NOW REQUIRED TORQUE =

T= P X 60 = 76.8 N-M
2 X 3.14 X N
= 836.6 Kg-Cm

FURTHER TORQUE T= 3.14 X fs X d³

16
WHERE
d= SHAFT DIA
fs= ALLOWABLE SHEAR STRESS = 0.3 X Ys = 840 Kg/Cm²

(MATERIAL FOR STUB SHAFT En8 UTS-5500 Kg/Cm² Ys-2800 Kg/Cm²)

d= 17.18 MM

SELECTED DIA OF SHAFT 50 MM > 17.18 MM

NOW SHEAR STRESS FOR 50 MM SHAFT

T= 3.14 X fs X d³ fs= 34 Kg/Cm²< 840 Kg/Cm²

16

HIN CMR 60 SMM ED 00 100 30 of 30