ametecs crane desigh & details

7/23/2019 Ametecs Crane Desigh & Details

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Brochure –Lifting Equipment

LIFTING EQUIPMENT

AMETECS

Al Makki Engineering & Technical Services, Plot 47, M-5, Mussafah Industrial Area,

Post Box 70362, Abu Dhabi, UAE

Tel: +971-2-5552426 Fax: +971-2-5540040

E-mail: [email protected]




Page | 1

Table of Contents

Introduction ............................................................................................................................................ 2

Types of cranes manufactured by AMETECS .......................................................................................... 3

Slewing Jib Cranes ................................................................................................................................... 4

Portable Davits ........................................................................................................................................ 6

Monorail cranes ...................................................................................................................................... 7

Overhead travelling cranes ..................................................................................................................... 9

Counterbalance Floor Cranes................................................................................................................ 12

Features of DELTA Manual Hoist: ......................................................................................................... 13

Gantry Cranes ....................................................................................................................................... 14

Design & Development ......................................................................................................................... 17

Explosion Proof Cranes ......................................................................................................................... 20




Page | 2

Introduction

AMETECS ( Al Makki Engineering & Technical

Services) was started in 1983 primarily as anOilfield Services Company. Since then, we

have ventured into the field of specialized

fabrication, design and manufacture of

special purpose machinery, material handling

and lifting equipment, penstocks, ASME-

Certified pressure vessels, aircraft ground

service equipment, storage tanks and

precision tooling.

AMETECS has a full-fledged, well-equipped

fabrication and machine shop in Mussafah

Industrial Area, Plot No 47 (M-5). We have a

covered area of approximately 1200 m2 and

an open area of nearly 1000 m2. Apart from

this, a CAD-supported design section with

qualified engineers has been established

available to develop special purpose

equipment. AMETECS is also under the

approved vendor list for various government

organizations in the UAE (ADSSC, ADNOC,

ADCO etc)

Time-bound service and cost-effectiveness

being our motto, AMETECS has successfully

enjoyed the patronage of all leading

petroleum companies in the UAE; along with

the Government and private sector

engineering or contracting establishments.

Several material handling equipment like jib

cranes, monorails, portable cranes etc have

been locally developed to meet specific

requirements and are working satisfactorily in

pumping stations for the past several years. Inspecial cases, alloy material have been used in

the construction of cranes and lifting systems;

thereby providing considering local conditions

and application environment gives goodtrouble free service life

AMETECS is also the authorized service and

Installation Company in U. A. E. for high-tech

specialized oil field electrical valve actuators

Bernard of France. We are one of the SPC

approved manufacturers of lifting and

handling equipment in the UAE.

Strict in-house quality assurance procedures

(to ISO 9001:2008) are followed to ensure

that the products delivered to our clients are

always of the highest quality.

AMETECS is also certified to manufacture

pressure vessels to ASME Sec VIII Div 1 (U-

Stamped) and also for repair of vessels to

National Board Inspection Code (R-Stamp).

We are also approved crane suppliers to

ADSSC, ADDC & Abu Dhabi Municipality.




Page | 3

Types of cranes manufactured by AMETECS

AMETECS has developed the following systems for use in the region:

- Slewing Jib Cranes (manual or electric; with slewing angles of 270o up to 360

o)

o Floor mounted (free standing)

o Wall mounted

-

Portable davits

- Monorail cranes

o Electric (with dual-speed motions in all directions)

o Manual

-

Overhead travelling cranes

o

Electrical (with dual-speed motions in all directions)

o Manual

- Counterbalance floor cranes

-

Gantry cranes

o

Manual light duty gantry cranes

Fixed height

Adjustable height

o Heavy duty electrical gantry cranes

-

Explosion proof cranes

We are capable of designing and developing lifting systems specific to

client/project requirements. All cranes are painted as per project specifications.




Page | 4

Slewing Jib Cranes

There are two types of slewing jib cranes that are manufactured by AMETECS:

1) Floor mounted (free standing)

Slewing jib cranes are the most versatile type of cranes. These are perfect for use in pump stations and

also underneath large bridge cranes; in open areas where it can serve several work stations. These

cranes can also be in used in loading docks or in machining and assembly operations where it can be

overlapped with other jibs to provide staged operation.

2) Wall mounted

The wall mounted jib cranes provide hoist coverage and 200o rotation for individual use in bays, along

with walls or columns. As this type of crane can be installed very close to the underside of the lowest

ceiling obstruction, this jib has the advantage of providing maximum lift for the hoist. Two important

requirements for this type of jib crane are:

-

A structurally adequate wall or column to support the jib must be present

-

Sufficient clearance above the boom throughout its arc must be present




Page | 5

Advantages of AMETECS floor mounted Slewing Jib Cranes

- Ease of operation

o

Loads can be positioned precisely, effortlessly and efficiently

o Precision tapered roller bearings in the fulcrum pin assembly provide smooth operation and

also extended life

o

Full supporting triangular base plate gussets are used to minimize the column deflection

o 270o slewing angle

- Ease of installation

o

Independent head assembly installs separately for ease of installation

o

Recessed bearing assembly allows greatly reduced clearances needed for installation

o Bolted head/arm connection which permits separate installation and provides maximum lift

for the hoist, since it can be installed very close to the underside of the lower ceiling

obstruction for greater headroom

o

Movable bolted trolley stops-

Safety

o

Fulcrum pin retaining plate provides resistance to accidental upward dislodgement of the

head

o

Overload protection as standard with electric hoists and optional with manual hoists

o

Arm lock mechanism (in stainless steel) to prevent unauthorized usage of the crane

- Power rotation

o Optional power rotation of the arm can be provided

Advantages of AMETECS wall mounted Slewing Jib Cranes

-

Ease of operation

o The fittings contain bronze bushings and oil-immersed thrust washers; which provide easy

rotation and superior load positioning

-

Ease of installation

o If the bracket centre dimension is 250 mm or less, the mast/jib connection is welded;

thereby providing the most economical means of installation

o If the bracket centre dimension is more than 250 mm, a bolted mast/jib connection is used;

which enables larger cranes to be transported disassembled for ease of handling during

installation

- Safety

o Pre-fabricated steel fittings that provide excellent torsional rigidity

o Overload protection as standard with electric hoists and optional with manual hoists

o

Arm lock mechanism (in stainless steel) to prevent unauthorized usage of the crane

-

Power rotation

o Optional power rotation of the arm can be provided




Page | 6

Portable Davits

We offer lightweight davits primarily designed for submerged pump recovery from wet wells or holding

tanks. These davits can also be utilized for pallet stacking, machine loading and other maintenance

operations. The davits are available in either galvanized steel or aluminum(up to 500 kg) or stainless steel

construction. The davits are demountable and portable with in-ground, surface mounted or wall mounted

sockets.

Portable lifting davits can be easily dismantled for storage or transportation to other locations, as the

individual components can be handled and moved manually.

Features

- Allows operator freedom to work close to

machines or over obstructions

-

Designed with safety in mind, this cranemeets all international safety standards

- Robust, all welded construction

-

Manufactured from hollow steel box

sections for combined strength and

lightness

-

Can be fitted with heavy duty, double acting

pump or hoist

- Hydraulic-pump models are fitted with

safety relief valve to prevent overload

-

Fitted with hard wearing polyurethane front

wheels and swivel castors on the rear for

easy movement of the crane when

operational

- Rear swivel castors have brakes fitted

- Safety latch provided with hoist/hook

-

Each crane to be individually tested to 25 %

overload as a complete unit

- Comes with a 12 month guarantee

-

Painting system is 3-coat; with PU top coat as color of choice

Options

- Either with hydraulic pump or manual hoist




Page | 7

Monorail cranes

Monorails are an economical choice for lifting and transporting products along a fixed path. Perfect for

processes like moving raw materials or pumps, a monorail system is mounted to an existing overhead

structure to preserve floor space. For hard to reach areas where a bridge crane cannot go or areas where

ceiling height is a problem, a monorail system provides the

access you need.

AMETECS manufactures electric and manual monorail

systems. The system consists of an I-beam, mechanical end

stops, mounting clamps and the hoist (manual or electric).

Monorails by AMETECS are custom designed to fit any

building. Standalone support systems for monorails can also

be furnished. Standard monorail curved sections and track

devices such as switches, turntables, interlocks and

entry/exit sections can be furnished for optimum flexibility

in a conveyor, monorail, or combination bridge crane

monorail system.

Advantages of AMETECS Monorail Cranes

-

Ease of operation

o Monorails with electric hoists are manufactured with two-speed hoists; to enable

convenient lifting/lowering of the loads

o

Monorails with manual hoists are provided with stainless steel SS 316 hand pull chain

o

Monorail systems with two or more beams can be developed; to provide greater flexibility.The various beams can be linked to one another with the use of interconnections

-

Ease of installation

o The beams are transported to site in smaller lengths; thereby making it easier and safer to

handle during installation

o

Custom made mounting clamps are provided for each beam section

-

Safety

o Monorails with electric and manual hoists are fitted with mechanical end stops (with rubber

bumpers)

o

In case of electric hoists, limit switches are also provided

o

Overload protection as standard with electric hoists and optional with manual hoists

- Interconnected monorails

o

Two or more monorails can be interconnected with the use of curved interconnections; if

needed




Page | 8

Monorail installed at Al Ain, Abu Dhabi Sewerage Services Co. (ADSSC) Project O-1797




Page | 9

Overhead travelling cranes

AMETECS manufactures completely customized overhead travelling cranes. These cranes are compact,

customized as per client requirements and are easy to operate and maintain. The overhead travelling cranes

can either be single or double girder; and are of two types:

-

Electric (EOT Cranes)

- Manual

Besides, the cranes can be designed to be either free standing (no existing support structure required) or

mounted inside existing structures.

Electric Overhead Travelling (EOT) Cranes

Electric Overhead Travelling (EOT) Cranes manufactured by AMETECS come with a complete two-speed

system as default (UP/DOWN/LEFT/RIGHT/FORWARD/BACKWARD). All controls are integrated into an

electric control panel that houses components like connectors, transformers, reverse contactors and fuses).

The control panel is with IP 65 protection.

The type of EOT can either be

1) Top Running (girder and end carriages move on top of runway beams)

2) Under-Slung (girder and end carriages move below the runway beams)




Page | 10

Advantages of AMETECS EOT Cranes:

-

Ease of operation

o Two-speed controls in all directions ensure that loads can be moved effortlessly and as per

operator preference

o

Soft start motors provided for all motions

-

Efficient installation of craneso The beams are transported to site in smaller lengths; thereby making it easier and safer to


o

AMETECS has a team of skilled workers specially trained for crane installation

- Safety

o EOT cranes are equipped with limit switches for all motions

o

Mechanical stops are also provided on the girder and runway beams; as back-up to the limit

switches

o

All electrical panels are rated to NEMA 1 as a minimum

o

Warning lights/siren can be provided as optional

o

Overload protection as standard feature in all EOT cranes

o Motor protection circuit breakers provide additional protection for the crane motors;

especially in severe inching operations

- Other features

o Heavy duty motors are provided to ensure long service hours without any breakdown

o

Modular design covers a wide operating range

o Various crane beam to end carriage constructions available to ensure optimum use of head

rooms

o

Standard hoists are low head room type; running on the bottom flange of the beam

o

Possibility to fit a walkway to the crane; to serve the purpose of maintenance access to

many critical parts

o

Radio remote controllers and automation feature are optional




Page | 11

Manual Overhead Travelling Cranes

These cranes are supplied with a manual hoist and manual geared end carriages. The end carriages are

inter-connected through a specially designed load shaft to transfer the pull force effectively. Even for

manual overhead cranes, the configuration can either be top-running or under-slung.

Advantages of AMETECS EOT Cranes:

-

Ease of operation

o Minimum effort needed for hoisting

o Geared end carriages provided for long travel

-

Efficient installation of cranes

o The beams are transported to site in smaller lengths; thereby making it easier and safer to


o

AMETECS has a team of skilled workers specially trained for crane installation

- Safety

o Can be supplied with overload protection on the hoist (optional)

o

Mechanical stops are also provided on the girder and runway beams

- Other features

o Modular design covers a wide operating range

o

Various crane beam to end carriage constructions available to ensure optimum use of head

rooms

o Rigid runways and superior load positioning – no movement or “crab-walking” of the bridge




Page | 12

Counterbalance Floor Cranes

Heavy duty counter-balance floor cranes are ideal

industrial lifting solutions where the lift must be

completed close to a piece of machinery or over

an obstruction; meaning a standard crane is not

suitable. These cranes are portable and trusted

across many industries and are suitable for

industrial/commercial use. The AMETECS range of

counter-balance cranes are available in ranges of

200 kg up to 2500 kg; and can be customized

completely to meet customer requirements. The

cranes can be easily moved in a workshop; as

they are fitted with heavy duty PU castors.

The Counter Balance Cranes are usually fitted

with hydraulic cylinders to enable lifting/lowering

of loads. In special cases where space restraints

are present, a fixed column with a manual hoist

can also be provided.

Features:

- Allows operator freedom to work close to

machines or over obstructions

-

Designed with safety in mind, this crane

meets all international safety standards

- Robust, all welded construction

-

Third-party MPI to be done all welds

- Manufactured from hollow steel box

sections for combined strength and

lightness

-

Can be fitted with heavy duty, double

acting pump or hoist

- Hydraulic-pump models are fitted with

safety relief valve to prevent overload

-

Fitted with hard wearing polyurethane

front wheels and swivel castors on the

rear for easy movement of the crane

when operational

-

Rear swivel castors have brakes fitted

- Safety latch provided with hoist/hook

- Hoist comes with ‘overload limiter’ to

prevent lifting of excess load

- Each crane to be individually tested to 25

% overload as a complete unit

-

Third-party certification can also be

provided- Test certificate to be provided with each

crane

- Comes with a 12 month guarantee

- Painting system is 3-coat; with PU top

coat as color of choice

Important Safety Information:

- Always inspect the hoist and latch before

using

-

Never use a latch that is distorted or bent

- Always make sure spring will force the

latch against the tip of the hook

-

The latch must never support the load

- Never attempt to lift more than the SWL

limit of the crane

-

This crane must never be used for lifting

personnel




Page | 13

Model shown to the left is with SWL 1000 kg

and bolted connections/fixed column, for a

special application. Hydraulically adjusted

arm can also be incorporated on request.

The hoist is of DELTA HOIST and comes with

an overload limiter.

Features of DELTA Manual Hoist:

-

Unit with overload limited kit

-

Precision machined and highly finished shafts, sprocket and

bearing housings

-

Brake system with steel protected shield

-

Roller bearing inside the chain sprocket supporting the load shaft

- Asbestos-free brake lining

-

Ratchet disc with double ratchet pawls

-

All steel structure and gearing design specially designed to fit up

to Grade 100 load chain

- A smoothly running hoisting device, even at the maximum load

-

Maximum effort to lift 1000 kg load is 304 N




Gantry Cranes

Dependable and versatile, gantry cranes from AMETECS offer cost effective lifting portability that

can withstand the heaviest of loads. Easily assembled and disassembled, these cranes can be used

indoors or outdoors, whether mounted or mobile. Gantries are successfully utilized across multiple

industries and can also be used in stockyards, scrap yards and railway yards. The gantry cranes can

also be moved to a new location with less trouble than a free-standing overhead crane. Also, it is

easy to extend the length of the runway and working area of gantry cranes. The cranes can also be

designed for completely automatic operation; by interfacing with a PLC (part of AMETECS scope).

The types of gantry cranes manufactured by AMETECS can be divided into two categories:

-

Manual light duty gantries

These cranes are of the A-Frame type and can be easily moved to any location in a facility.

This type of crane is cost effective for areas with infrequent lifts. There are again two types

of manual gantries:

a. Fixed Height

These cranes are available in fixed heights

depending on the requirement. Square tubing

uprights, knee braces and channel bases are used

to provide stable lifting and movement. The beam

is bolted to the upright to ensure safe connection.

The standard model is supplied with molded

phenolic casters for easy movement.

b.

Adjustable Height

These gantries are similar in construction to

the fixed height; but the square tubing

uprights are capable of movement in outer

sleeves. Depending on the height required, the

upright can be bolted on to the outer sleeves.

Maximum heights on this system range from 7

feet to 14 feet. The other features remain

same as the fixed height gantry.

The light duty gantries can also be supplied with electric hoists (optional). In addition, thelight duty gantries can also be manufactured in light weight aluminum structure (up to SWL

of 3 t). More details of the light weight gantry cranes will be furnished on request.




Page | 15

- Heavy duty electric gantry cranes

Powered gantry cranes are typically used for larger, high capacity jobs where operators

require less manual features. The standard configuration is A-frame type. However, for

applications that cannot have traffic on one side of the crane, AMETECS can develop single-

leg gantry cranes. All powered gantry cranes are furnished with motor drives to ride on V-

groove track crane rail directly on the floor by use of PU wheels. For outdoor and higher

rated cranes, double flanged wheels are used.

Heavy duty electrical gantry cranes from AMETECS are designed to provide dependable,

durable lifting solutions. Each crane is manufactured in line with all relevant international

standards.

To summarize, the following types of gantry cranes can be manufactured by AMETECS:

1)

Trackless gantry with floor guide

These cranes are ideal for applicatons requiring a

gantry to run against a wall. A guide angle lags to

the floor along the wall guiding the guiding which

directly travels on the floor on PU wheels.

These types of cranes can also be used in open

areas where a guide angle on the floor is not

practical. A selector switch can be incorporated in

the control panel to selectively turn each motor

ON and OFF to compensate for skewing.

2) Single leg, top running end carriage

The single leg design maximizes space utility in confined,

narrow areas by traveling down an aisle on PU wheels

while the other end of the I-Beam mounts on an end

truck travelling on an overhead runway.

3)

Single leg, under slung end carriage

A single leg gantry can also be used with an under slung

end carriages on one side which travels on the bottom

flange of an overhead runway beam.




Page | 16

Gantry crane installed at Qatar Steel (Masaeed, Doha), 4 T SWL, with grab. Crane is PLC controlled

for complete automatic operation.




Page | 17

Design & Development

AMETECS is equipped with a fully-fledged design department specific to lifting equipment. Our

trained personnel help in providing our customers with most suitable lifting system. All design is

performed on exclusive design workstations and using the latest software; thereby totally

eliminating the need for shop testing of models before complete fabrication. This has resulted in a

great saving of time and cost; which in turn benefits the end user. All design calculation results are

incorporated in our technical submittal; providing total clarity to the client and consultant at the

time of review.

Few snap shots of our design outputs are shown below:

Design of jib crane – deflection diagram Design of jib crane – foundation forces




Page | 18

Design of free standing EOT – deflection diagrams

Design of free standing EOT – member strength check




Page | 19

Design of free standing EOT – foundation forces




Page | 20

Explosion Proof Cranes

AMETECS has manufactured a wide range of explosion proof hoists, with close awareness of the

customer requirements. Our explosion proof cranes have been used in various fields such as

chemicals, oil & gas where safety in production is evident. All hoists used by us with our explosion

proof cranes are according to the new ATEX 100a (94/09/CE applicable in 2003) and CE regulations

(CE marking, documentation, CE certificate approval).

Hazardous areas are defined by three main criteria:

-

The type of hazard

- The likelihood of the hazard being present in flammable concentrations

- The (auto) ignition temperature of the hazardous material

Type of hazard (Groups)

The hazard will be in the form of a gas, vapour, dust or fibre.

Gases and vapours are categorized in terms of their ignition energy or the maximum experimental

safe gap (in respect of flameproof protection). This categorization leads to the Gas Groups:

Mining Surface Industry

Group I Group II

Methane

IIA IIB IIC

Propane Ethylene Hydrogen

Group IIC is the most severe group. Hazards in this group can be ignited very easily.

Dusts and fibres are classified under Group III. Dusts and fibres are also defined in terms of their

ignition properties including dust cloud ignition properties.

Likelihood of the hazard being present in flammable concentrations (Zones)

The likelihood of the hazard being present in flammable concentrations will vary from place to

place. A location very close to an open source of hazard will have a high likelihood of a flammable

atmosphere. On the other hand, outside a flanged pipe containing a flammable liquid, the likelihood

of a flammable atmosphere being present is much lower since it will only occur if the flange

leaks. Rather than work with an infinite range of possibilities, three zones are defined.

Gases and Vapours

There are three zones for gases and vapours:




Page | 21

Zone 0Flammable atmosphere highly likely to be present – may be present for long periods

or even continuously

Zone 1 Flammable atmosphere possible but unlikely to be present for long periods

Zone 2

Flammable atmosphere unlikely to be present except for short periods of time –

typically as a result of process fault condition

Zone zero is the most severe zone (the highest probability of flammable atmosphere

presence). Equipment for this zone needs to be very well protected against providing a source of

ignition.

Dusts

There are three zones for dusts:

Zone 20 Dust cloud likely to be present continuously or for long periods

Zone 21 Dust cloud likely to be present occasionally in normal operation

Zone 22Dust cloud unlikely to occur in normal operation, but if it does, will only exist for a

short period

Ignition temperature of the hazardous material (temperature classes)

As well as considering the protection against electrical arcs and sparks igniting a flammable

atmosphere, consideration needs to be given to the surface temperature of equipment. (Most

electrical apparatus dissipates some heat!) Flammable materials are categorized according to their

ignition temperature. Again, rather than work with an infinite range, six temperature classes are

defined as follows:

T-ClassHazards will not ignite at temperatures

below

T1 450oC

T2 300oC

T3 200oC

T4 135oC

T5 100oC

T6 85oC

The bigger the T-number the lower is the temperature.

The Temperature classification will be marked on items of equipment. If the hazardous area in which

you are installing equipment has gases or vapours with a low auto-ignition temperature then you will

need equipment with a bigger T-Number so as to ensure that any hot surfaces on the equipment will

not ignite the hazard.




Al Makki Engineering and Technical Services Ltd, Plot 47, M-5, Mussafah Industrial Area,

Post Box 70362, Abu Dhabi, UAE

Tel: +971 2 5552426 Fax: +971 2 5540040

E-mail: [email protected]

ametecs crane desigh & details

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