1. Pre-Erection Preparations
Before beginning the erection, certain preparatory steps must be taken:
- Site Inspection: Assess the installation site for space, structural support, and safety conditions.
- Foundation & Rail Alignment: Ensure that the crane runway girders and rail alignments are correctly installed.
- Material Inspection: Verify that all crane components (girders, end carriages, hoist, motors, panels, etc.) are as per specifications and free from defects.
- Tools & Equipment Preparation: Arrange necessary tools, lifting tackles, welding machines, and other required equipment.
- Safety Precautions: Ensure that workers wear PPE (helmets, gloves, safety harnesses, etc.) and that the work area is secured.
2. Erection Process
- Assembly of Crane Components:
- Align and position the crane main girders.
- Attach end carriages to the main girders securely.
- Mount the trolley/hoist unit onto the main girder.
- Rail & Runway Alignment:
- Check and align the rail track to ensure it is level and parallel.
- Secure rail clamps, buffers, and end stops.
- Electrical Installation:
- Install the power supply system (DSL busbar, festoon cables, or conductor system).
- Connect the motors, control panels, and pendant/remote control wiring.
- Properly ground all electrical connections to avoid hazards.
- Final Tightening & Bolting:
- Ensure all bolts and fasteners are tightened as per torque specifications.
- Perform welding where necessary for structural integrity.
3. Commissioning Process
- Initial Checks & Testing:
- Inspect all mechanical and electrical connections.
- Check lubrication of gears, bearings, and other moving parts.
- Ensure limit switches, brakes, and emergency stop mechanisms are functional.
- Load Testing:
- Conduct a no-load test to verify smooth movement of the crane, hoist, and trolley.
- Perform a load test using 100% and 125% of rated capacity to check performance under full load conditions.
- Operational Trials:
- Verify crane speed, braking efficiency, and overall control system.
- Test safety features like overload protection and emergency stop.
- Conduct trial operations with the operator to confirm ease of handling.
4. Handover & Documentation
- Provide a commissioning report, including test results and safety checks.
- Deliver operational and maintenance manuals to the client.
- Train operators on proper usage and safety guidelines.
After successful testing, the crane is declared fit for operation and handed over for regular use.
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