Here at Crane Services we always consider the modification or conversion option first. If the current structure is essentially sound, then we can offer a considerably more cost effective solution compared with complete replacement.

For a relatively modest investment you may well be able to upgrade your existing crane system to one that operates at modern efficiency levels – recovering the initial costs in a relatively short period of time through improved efficiency and lower operating costs.

Crane modification

Todays sophisticated electronic control equipment is a world away from conventional systems yet can be applied to your existing crane at a relatively low cost. Our engineers can make a full appraisal and provide a competitive quotation for converting your crane.

So, if you have been asking yourself the question of whether to replace existing lifting equipment or to make do, it may well be worth giving us a call.

Ultra Dynamics sought a solution to power the slew function of the jib crane and modify the control system whilst ensuring the existing production environment was not effected and no down time was experienced. Not an easy task.

Our solution

The jib had an existing roller frame constructed of two bearing rollers which ran on a flat belt of steel around the radius of the jib post. We chose to design a new twin wheel roller frame with deeper wheels to increase the surface area contact, both driven by live axle drive motor gearboxes to ensure an even pull when slewing.

On completion of the fabrication the jib arm was removed on site and transported back to our factory to allow the new powered roller frame to be installed. The pendant was changed and the electrical control system was reconfigured to fit a frequency inverter drive to the powered roller frame motors to allow fine speed control and gentle acceleration and deceleration of the slewing motion.

 In addition, the top bearing was replaced and a lubrication point was machined to allow the bearing to be lubricated without the need for removing the jib arm.

 The Result

 We provided and installed a cost effective method of improving the safety and control of their lifting application along with a reduction in requirement for manual handling and the associated risks. Ultra Dynamics are loading extremely valuable engines into test rigs and jigs therefore fine control and positioning to ensure the safety of their components is of the utmost importance.

 A job well done!

The government is currently reviewing all health and safety legislation and the associated ACoPs and guidance with a view to removing over-onerous requirements. However, the inquiry which led to the review had found that the problems often arose from overzealous application of the requirements rather than the legislation.

Keeping up to date with standards and legislation can be a minefield at the best of times. As a specialist in the overhead lifting industry it is a vital requirement for us to keep up to date with new legislation and changing standards. To help share information we’ve provided a summary of standards and legislation changes reported from a recent LEEA meeting held this April.

Standards

EN13155

It was agreed to recommend to CEN/TC 145 that issues relating to elevators in the offshore industry be dealt with a separate standard. A new draft was prepared by a simple expedient of deleting everything from the initial enquiry draft that was not relevant to elevators.

Certain comments remain to be considered but it was clear that with the exception of the UK, all countries had reviewed only the new material on elevators and had not reviewed the rest of the standard.

BS 7121-2

MHE/3/11 dealing with the revision of BS 7121-2 has set up 3 panels to consider the drafts of sub parts 2-1 (general), 2-3 (mobile cranes) and 2-7 (overhead cranes and hoists). A draft of 2-7 on behalf of LEEA based it on the new COPSULE section. The panel for 2-1 met on the 13^th March, the panel for 2-3 on the 14^th March and the panel for  2-7 on the 15^th March.

The BSI content developer has sent out revisions of all 3 panels for review. The content developer will now prepare them for enquiry.

Standards due for Review

The following standards are due for review:

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Below-the-hook equipment is particularly significant because it is responsible for securing the load during the lifting operation.  Short of an overload or deliberate abuse, there is a relatively low risk of damage to equipment such as overhead travelling cranes, however a sling is vulnerable each and every time it is used.

Failures in planning often manifest themselves in the misuse of lifting attachments and slings. Faced with an awkward load, there is a tendency in some quarters to try and make do with general purpose slings rather than obtain more specialised solutions. The irony is that equipment tailored to the characteristics of the load and lifting operation not only makes the job safer, but also much more efficient. This is particularly true when a series of identical items are to be lifted. Often the purchase price of an alternative attachment is relatively low and hire can sometimes prove an even more economic option.

The problems inherent in using inappropriate below-the-hook equipment can generally be avoided with a little advance preparation. This should include taking the time to create a specification for the lifting equipment – this spec should include the characteristics of the load and the proposed manner in which the equipment will be used. The buyer should also consider how the equipment will be released once the component is in place, and warn prospective suppliers of any adverse environmental factors.

Given the tough life experienced by many slings and lifting attachments, it pays to invest in quality products. In this respect, an appreciation of Harmonised European Standards (CEN) is helpful; a product made to the relevant CEN is deemed to meet the essential health and safety requirements demanded by the Machinery Directive. As far as below-the-hook items are concerned, EN13155: 2003 Cranes – Safety – Non-fixed load lifting attachments, is particularly significant. With the exception of general purpose slings, this encompasses just about anything that can be hung from a crane hook. In the absence of a relevant CEN, buyers should specify the relevant national standard.

Clearly such precautions can go some way to ensuring that below-the-hook equipment is sufficiently robust. However, once the equipment is purchased, it should be subject to a proper programme of thorough examination, as outlined in the Lifting Operations and Lifting Equipment Regulations (LOLER) and accompanying codes of practice. Equally, such thorough examinations should be supplemented by regular in-service inspection. Given their vulnerability and critical role, slings and load lifting attachments should be subject to such an inspection every time they are used and withdrawn from service for repair or disposal if there are any concerns over their safety.

In a tough commercial climate, the temptation to cut back in all areas of capital expenditure is obvious. However, when it comes to below-the-hook equipment, even modest investment can often reap dramatic rewards. Across a wide range of industries and applications, time and money is being wasted by companies using the wrong equipment.

With over 50 years in the overhead lifting industry, we are well versed in providing a review and maintenance service to help detect issues before they take hold, helping you and your organisation to stay safe and in business.

 Article Extract from LEEA.

Sapa Pole Products recently opened a new facility in the Midlands for the storage of stock aluminium lamp posts. The depot holds stock to enable them to offer a “trade counter” supply to local utilities companies. Whilst being ideal for their space requirements, the building housed some heavy duty Demag double girder overhead cranes, which were quite antiquated for the requirements of the company.  Sapa needed to lift long lengths of product, preferably on two points, to ensure safe and level control of the load and accurate alignment when being stacked.

Our brief was to provide a safe and efficient method of lifting long lengths, preferably with a tandem lift, whilst minimising the project cost by utilising the existing cranes. We also needed to ensure the cranes could be returned to their original condition in the future.

Utilising the existing structures we removed the existing foot mounted hoist units, created a new mounting frame with two new hoists positioned to the outside of the existing crane box girders, which provided a tandem lift at increased lifting centres. This allowed for greater control of the product being lifted. The hoists were high speed wire rope hoists, which were permanently attached to a purpose designed lifting beam. This incorporated multiple slinging positions for different lengths of product and a central lifting hook for general duties.

Like many metal processing businesses, Zotic Ltd, who offers a case hardening service to many industrial sectors, had struggled to find a lifting solution that could cope with the extreme temperatures involved in their production processes.

With several heat treatment pots running under an extraction canopy where the ambient temperature can be as high as 200˚C to 250˚C, finding a lifting solution that could handle such temperatures was key. Originally the system used manual lifting equipment mounted on a single runway beam at the top of the canopy. Due to the increased process speeds required and concerns over Health and Safety, Zotic needed an electric hoist which was capable of operating in such arduous conditions, whilst being controlled from a safe distance. They had already been supplied with numerous electric chain hoists which had quite literally “melted” in the environment.

Crane Services designed a purpose built hoist application.  This was mounted outside the canopy in the roof structure where the ambient temperature is a more acceptable 30˚C. The hoist was fitted to the roof trusses with a bespoke sub frame chassis which incorporated a diverter sheave to allow for a horizontal feed of the rope drum. The rope was then diverted through a small opening into the canopy, around the bottom hook block sheave and then back up out of the canopy to an anchorage point. This ensured that only the rope and the hook block were ever subjected to the higher temperatures, both of which are not as susceptible to the effects of heat.

Any transmitter can be damaged or lost, and in most cases, a customer needs to call a crane engineer to fit the back-up pendant.   With Flex Radio systems, the spare transmitter keeps the crane operational, whilst the primary transmitter is repaired or replaced, usually within 24 hours or while-you-wait.

There are many benefits to our Flex Radio Control system. To find out more click here

Flex proportional push-button systems.   This option, available in 2012, will provide the option of fully proportional push button control for inverter controlled hoist and travel motions, along with a host of many other uses such as diesel throttle control, hydraulic actuators and proportional valve control for mobile plant and equipment.

New Flex Joystick system

Documents available for download

If you need to refer to any documentation relating to the application, adjustment or repair of Flex Radio systems, these are available to download from our web site at www.craneservices.co.uk

•  Essar Steels specify Flex Radio Control for their new 40t capacity coil carrying Demag overhead travelling crane due December/January“Their staff are extremely knowledgeable and professional and, unlike competitors radio control systems that are fragile and unreliable, we have found Flex Radio to be a perfect addition to our lifting and moving solutions. We now have Flex Radio Controls systems on all of our cranes.”

  Martin Skidmore, Essar Steel

•  Barnshaws, the world’s largest steel bending company, specify Flex Radio Control for their 3 new Demag Overhead Travelling Cranes.