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Chapter One
Introduction
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1.1 Origin of the report
This report has been prepared as an integral part of the internship program for the Bachelor of
Science in Mechanical Engineering (BSME) at the Department of Mechanical Engineering,
International University of Business Agriculture and Technology. The Greenland
Technologies Limited was nominated as the organization for the practicum while honorable Md.
Sharifuzzaman, faculty of Mechanical Engineering Department, rendered his kind consent to
academically supervise the internship program.
1.2 Objective
The broad objective of this project is to understanding the basic Service and Maintenance of
DEMAG Cranes and Components:
To be Familiar with different types DEMAG Cranes and Components.
To be Familiar with different parts DEMAG Cranes and Components.
To be Familiar with application of DEMAG Cranes and Components
To be Familiar with Manufacturer of DEMAG Cranes and Components.
To study on Operation of DEMAG Crane and Components
To study on Service and Maintenance of DEMAG Crane and Components.
To make an analysis on the Service & Maintenance activities of DEMAG Crane and
Components.
To know how to maintain Safety of DEMAG Crane and Components Saving in
manpower.
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1.3 Scope
The report will cover the Service and Maintenance of DEMAG Crane & Components, through a
broad knowledge of different kinds of mechanical and Electrical Parts. Knowing operating
systems of crane, their routine Maintenance process and different mechanical systems were
learned and it is the main scope of discussion in this report. .As crane is consisting Mechanical &
Electrical there was scope of learning both electrical and Mechanical activity. I did some work
on Hoist Motor, Gearbox, and Travelling Trolley in Dhaka Power Distribution Company limited,
Summit Power Limited and Bangla Trace Limited. To apply this technical knowledge, the scope
is limited in Bangladesh. But hopefully, in near future the scope is going to be widened.
1.4 Background
Today, more than ever, engineering applications are often interdisciplinary, involving the
interrelationship of several of the basic engineering science. Therefore the modern engineer must
have a fundamental knowledge in each of these theoretical and practical areas. To make a bridge
between theoretical knowledge to the practical knowledge by arranging this type of industrial
training results an engineer build up own criteria very much widely in practical life.
1.5 Methodology
A very standard service Team is organized in Greenland technologies Limited for DEMAG
Crane & Components. They are working in some contract maintenance work with those
company has Annual Maintenance Contract with Greenland Technologies Limited and also they
giving services in various Plant. Greenland organized their service by a Service Engineer with
one Sr. Technician and one Jr. Technician. They use check list as quality tools. They are
following some methods to ensure service & maintenance.
1. Crane Operation Manual.
2. Previous Service Record.
4. Crane Maintenance Manual
5. Check sheet of Crane.
7. Plant Management Manual
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1.6 Limitations
During practicum in Greenland Technologies Limited, I have got a lots of information and they
are very much cooperative and they help me a lot. As a fresh graduate it was very much easy,
understanding also interesting all the technical term for me. But some time it was not easy to
work with their service engineer because to work Crane service it’s require going above of the
crane which usually install up on the core bell of column. In this practicum I also get chance to
meet with some DEMAG Crane engineer those were came from India but I could not work with
them because of safety issue. After all it was very good time.
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Chapter Two
Company Overview
2.1 Greenland Technologies Limited, a Concern of GETCO Group
Greenland Technologies Limited is a private limited company. Since inception in 1972, GETCO has successfully concluded business in various sectors. Experienced, efficient, and dynamic leaderships are at the helm of the company’s management hierarchy. A group of overseas-educated young persons is supporting the management.
Greenland Technologies Limited provides sales, services, after market support, consultancy services, etc. to government, semi-government, and private organizations. Customers dealt with consist of sectors like Industrial Equipment, oil & gas, infrastructure, telecommunications, power, railways, defense, industry, etc. through various companies under the GETCO Group.
Greenland Technologies Limited represents world best manufacturers products and they provide Sales & service. Recently, Greenland Technologies Limited has Supplied Carne to Khulna Power Company Limited, Bergen Engines Bangladesh Limited, Epyllion Group Etc. beside Sales they are also providing service to Abul Khair Steel Limited, Siemens Bangladesh Limited, Summit Power Comilla Plant etc.
Overall Greenland Technologies Limited also has some others product such as Fork Lift, Cleaning Item- Sweeper Machine, Scrubber Machine, Vacuum Machine Etc and they also have air compressor. All this products manufacturers are German Origin. Greenland Technologies Limited is Supplying all this product in Bangladesh. They are doing both sales & Service.
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2.2 DEMAG Crane Manufacturer Overview
DEMAG Crane which is a 200 Years old Cranes Brand, still it is in number one brand in all over
the world. The DEMAG Cranes Group manufactures products in the industrial Cranes , Cranes
components. DEMAG has 16 Manufacturer plant all over the world. DEMAG has supplying
their sales and service of the products through subsidiaries, agencies and joint venture . To
provide rapid service DEMAG has 220 Service Location in 60 Countries. For the South Asia
region Terex Cranes & Components (I) Private Limited is the Dealar of DEMAG Cranes and in
Bangladesh Greenland Technologies Limited is the Sub-Dealar of Terex Cranes & Components
(I) Private Limited. Whether it operate cranes, hoists, load handling attachments or other related
equipment from DEMAG or any other manufacturer, we are able to offer a comprehensive and
innovative range of service activities to support the entire life cycle of your lifting equipment
from a single source. DEMAG Services is a national leader in providing maintenance and
product solutions for all major brands of overhead material handling equipment. We have proven
expertise with effectively providing inspection services that are tailored to customer needs and
application environment.
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2.3 Chairman Message
GETCO Group is established with a view to alleviate poverty by generating employment
opportunities. Over a period of time, the group has engaged over 10,000 collective work forces
which include efficient and talented human resource as well and thus contributed towards
economic development of the country. We endeavor to reach our products and services at the
client's doorstep through a network of sales and Service outlets. Human resources are our key
asset, who translates the group's objectives into realistic performance. We are committed to
have the best people and train them to get the best from them. Ours is a free market economy,
where private sector plays a key role in establishing an industrial base. We are striving to
expand our industrial portfolio to meet the needs of a growing population. Starting from two
product sales and service by GETCO Limited now it’s a Big group in trading Business. Right
now GETCO group has more than seven Limited companies. All companies have successfully
supplying their products sales & service. We believe in new ideas and technology, which leads
to bright future. We shall travel the road leading to future of immense opportunities hand in
hand with our customers and our employees to seek and find prosperity for the Group and the
country.
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2.4 GETCO Group
Greenland Technologies Limited
Greenland engineers and Tractors Company
GETCO Online Limited.
GETCO Techno labs Limited.
GETCO Digital Limited.
GETCO Ventures International.
GETCO Limited.
GETCO Agri-Technologies Limited.
2.5 Corporate Office:
GETCO Group26 Shyamoli, Bir Uttam A. W. Chowdhury Road (Mirpur Road)Dhaka 1207, Bangladesh
Phone: + (8802) 58151790 + (8802) 58151282
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Web: www.getco.com.bd
Email: [email protected]
2.6 Company Key Persons
Directors
K. M. Khaled Gole Afroz Banue K. M. Rakib Hasan K. M. Sakib Hasan J. P. Alam M. A. Khaleque
Key Personnel
Dr. Mosharrof Hossain Samad Parvez Dr. Shamim Akhter Uzzal Masba Uddin Ahmed Khokon Gain
2.7 Vision
The Vision of Greenland Technologies Limited is to become the leader of country for supplying
Industrial and Agricultural equipment all over the country. To make this vision Greenland
Technologies Limited is going ahead with their world class brand and young, energetic
employees. They are trying to establish themselves as sales and service provider of their existing
product range.
2.8 Mission
As Greenland Technologies Limited is a concern of GETCO Group and they are a trading
company. They are trying to establish various ways to execute their vision. Greenland
Technologies Limited appointing very young and energetic engineers for their sales and service
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work. Gradually the company providing training to their engineer in local office as well as they
is sending their engineer to abroad to the product manufacturer for training regarding the
products. After getting Train from Manufacturer the engineers work in difference sector all over
the country. Greenland Technologies Limited is also taking regional office in difference location
of country to give proper service to customer. The overall Greenland Technologies Limited
working hard to achieve their vision.
2.9 Greenland Technologies Limited Management Structure
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Chairman
Managing Director
Head of Operations
Manager Service
ManagerKarcher, Sales
ManagerFork lift, sales
ManagerNew Holland, Sales
ManagerDEMAG, Sales
Service CoordinatorDEMAG
Service CoordinatorKarcher
Service CoordinatorFork Lift
Service Engineers
Service Engineers
Service Engineers
Sr. Executive
Executive
Jr. Executive
Sr. Executive
Sr. Executive
Executive
Jr. Executive
Sr. Executive
Sr. Executive
Jr. Executive
2.10 Greenland Technologies Limited
Greenland Technologies Limited is a dream project of GETCO Group. They just started their
journey in 2014 and they are developing very well in Industrial & Agricultural equipment sales
and service all over the country. Greenland Technologies Limited was started their journey with
only one product Air Compressor, but within in this short time they are supplying four other
product in our country. Supplying products of Greenland Technologies Limited are DEMAG
Cranes & Component, Fork lift, Cleaning item, New Holland Tractor. Most important thing is
that the entire products manufacturer is German origin. Right now all over Bangladesh in
different sector of industry, institute, power plant, corporate offices if we search we would found
supplied products Greenland Technologies Limited. Most of the Power plant there is existing
DEMAG Crane. Most of the Institute, Hospital there is existing Greenland Technologies Limited
cleaning item such as sweeper machine, scrubber machine, vacuum machine etc. in our
university there is also a cleaning machine which is supplied by Greenland Technologies
Limited. Overall Greenland Technologies Limited is one of the best growing Company in our
country.
2.11 Greenland Engineers and Tractors Company
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Executive
Jr. Executive
Greenland Engineers & Tractors Company Limited deals with various world-class manufacturers,
distributors, & service providers in the fields of Defense, Aviation’s, Telecom, and Oil & Gas.
2.12 GETCO Online Limited.
GETCO Online in the name of HRC Technologies Limited is a customer satisfied Internet Service Provider
and with an experienced team of industry experts, HRC Technologies Limited aims to lead the Internet
service provision of Internet Access, Corporate Private Networks (Intranet) and Corporate Broadcast
services. The HRC Technologies Limited management has years of experience on IT & Telecom sector in
Bangladesh and abroad.
2.13 GETCO Techno labs Limited.
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Launched in 2011, with the mission of becoming the leading software development and IT services company in Bangladesh, has entered into strategic alliance with global software giants such as SAS Institute (which is the largest privately owned software company in the world based in Cary, North Carolina, USA). Our alliance with SAS Institute has resulted in the recent award of a 3 year contract by the country's largest mobile phone operator Grameenphone Ltd. to SAS Institute for the supply, implementation and maintenance of advanced data mining solution.
2.14 GETCO Digital Limited
GETCO Digital is a newly established Company of the GETCO Group, and will be mainly involved in IT projects. The company will provide business applications which are designed to integrate all the operations of an organization. Some of these applications are ERP, HRM and CRM solutions. Other areas of business include software export, graphic and web design export, vehicle tracking system, hospital management system, hotel management system, barcoding for warehouses and remote IT support.
2.15 GETCO Ventures International.
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Launched in 2011, GETCO Ventures International aspires to be the leading financial and strategic advisory services company in Bangladesh. Within weeks of its debut in Bangladesh, the company achieved name and fame in the corporate world by being engaged as the exclusive financial consultant on a BD Taka 5000 cores (US$640 Million) residential and commercial real estate development project by a major business group and real estate holding company.
2.16 GETCO Limited
GETCO Limited represents a number of world renowned manufacturers, distributors, and service providers as their dealer, distributor, agent, and consultant in the areas of Power Generation, Transmission & Distribution, Infrastructure building, Transportations, Equipment Sales, IT, etc.
2.17 GETCO Trading Limited
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GETCO Trading Limited deals with sales of CNG Compressors for refueling stations, sales, & service of gas and diesel engines/generators, rental of diesel engines, etc
2.18 GECO Agro Vision Limited
GETCO Group formed GETCO AGRO VISION Ltd. (GAV) in 2006 with a vision to utilize modern science and technology in Food and Agriculture. GAV has created an excellent opportunity in research & development towards innovative products of high quality F1 Hybrid, OP and Organic seeds of vegetables, potato, rice, maize, herbs, and flowers.
2.19 GETCO Agri Technologies Limited
GETCO has established a Plant Tissue Culture laboratory and started its activities from July 2010. Tissue culture has been exploited to create genetic variability from which crop plants can be improved. This technology also helps to improve the state of health of the planted material and to increase the number of desirable germless available to the plant breeder.
2.20 GETCO Telecommunications Limited
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This company is the latest addition under the group umbrella. GETCO Telecommunications Ltd. got an award of a telecommunications operator license for Inter Connection Exchange (ICX) in February 2008 from Bangladesh Telecommunications Regulatory Commission (BTRC) for a period of 15 years with provision of another 10 years extension. In August 2008, the company started its operation.
2.21 Regional Office of GETCO Group
Dhaka
Chittagong
Rangpur
Josser
Khulna
Comilla
Dinajpur
Kustia
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Chapter Three
Types of Cranes
3.1 Different Categories of Crane
Standard Crane
Process Crane
KBK Crane
JIB Crane
Portal Crane
Semi Portal Crane
3.2 Standard Crane
Standard solutions made by DEMAG offer outstanding quality, efficiency, and reliability at the
highest level. Every crane and every crane component reflects decades of crane expertise and
reliability as a partner for the industry. With the new DR rope hoist, DEMAG Cranes &
Components has introduced a state-of-the-art standard for crane applications with loads weighing
up to 50 MT and, at the same time, an entirely new crane philosophy. Capacity of standard crane
is start from 3.2 Ton and it can carry load of maximum 50 Ton.
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Single-girder overhead travelling cranes with box-section girders
SWL to 10 t
Span to 30 m
Long travel speed to 40 m/min
Cross travel speed to 30 m/min
Hoist speed to 12.5 m/min
Single-girder overhead travelling cranes with rolled profile girder:
SWL to 5 t
Span to 15 m
Long travel speed to 40 m/min
Cross travel speed to 30 m/min
Hoist speed to 12.5 m/min
Suspension cranes – the column-free alternative
SWL to 5 t
Span to 14 m
Long travel speed to 40 m/min
Cross travel speed to 30 m/min
Hoist speed to 12.5 m/min
Double-girder overhead travelling cranes – high load capacities Combined with wide spans
SWL to 50 t
Span to 30 m
Long travel speed to 40 m/min
Cross travel speed to 25 m/min
Hoist speed to 12.5 m/min
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Classification of Standard Crane
1. Single Girder Crane
2. Double Girder Crane
Figure 1: Single Girder Crane
Single Girder Crane Technical Data
Capacity of Crane: Minimum 500 KG up to maximum 12.5 Ton.
Span: Minimum 2.5 M up to Maximum 30 M.
Travelling Speed (Lifting): Minimum 1 m/m and Maximum 6 m/m.
Figure 2: Double Girder Crane Double Girder Crane Technical Data
Capacity of Crane: Minimum 3.2 Ton up to maximum 50 Ton.
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Span: Minimum 5 M up to Maximum 50 M.
Travelling Speed (Lifting): Minimum 1 m/m and Maximum 5 m/m.
3.3 Process Crane
Figure 3: Process Crane
DEMAG process crane is manufacture for particular purpose such as when it is require to take
load more than 50 Ton then the process crane is used. Most of the time in Power Plant, Steel
mills and port where there is heavy weight machine require to move for maintenance or heavy
weight steel bar require to move on that time process crane is used.
Capacity of Crane: Minimum 50 Ton up to maximum 400 Ton.
Span: Minimum 20 M up to Maximum 70 M.
Travelling Speed (Lifting): Minimum 1 m/m and Maximum 4 m/m.
3.4 KBK Crane
Figure 4: KBK Crane
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DEMAG KBK Crane also called crane construction KIT, which is special purpose usages crane.
Where there is a less space to setup crane and the weight of object is less than 3.2 ton then the
manufacturer suggest to customer to setup KBK Crane. Most of the time KBK crane setup in
inspection shop, Auto mobile industries, various small components manufacture industries, Firm
house etc. KBKB Crane minimum capacity is 125 kg to maximum it can take 3.2 Ton capacity.
3.5 JIB Crane
JIB Crane is the type of crane which has rotating motion. It can rotate up to 360 degree. JIB
cranes are two types one is pillar mounted JIB crane and another is Wall mounted JIB Crane. JIB
crane can take maximum weight 5 Ton from starting any amount of weight. The difference
between Wall mounted and pillar mounted is that wall mounted JIB Crane can travel along the
wall, but Pillar mounted JIB Crane cannot travel.
Figure 5: Wall Mounted JIB Crane
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Figure 6: Pillar Mounted JIB Crane
3.6 Semi Portal and Portal Crane
Semi portal and Portal crane this two cranes are manufactured by DEMAG Crane manufacturer
for outdoor solution where there is no shade to setup on that time portal crane can be setup for
example; Port area, semi portal is setup for those purpose where one site of the shade can be used
but another site cannot be used on that time semi portal crane set there one end of the crane will
run on runway beam another end will run on floor. In portal and semi portal crane SWL is 3 Ton
to up to 50 Ton and the span of the crane can be maximum 30n Miter.
Figure 7: Semi Portal Crane
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Figure 8: Portal Crane
3.7 Under slung Crane
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Figure 9: under slung Crane
Under slung crane is used in very particular places where there is not enough space to setup
crane on the bay length then Crane manufacturer suggest for under slung crane. Under slung
crane only be single girder and its SWL- Safe Working Load is maximum 10 Ton. The span of
under slung crane is 25 Miter.
Chapter FourManufacturing Details
4.1 DEMAG Crane Manufacturer overview
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Manufacturing Location in Chakan, Pune, India
Total area: 12.7 Acres
Office area: 2000 sq. mts
Manufacturing facilities: 11300 sq. mts
4.2 DEMAG Crane Manufacturer Details
DEMAG is a origin brand of German, which is 200 years old brand, as they extended their
business all over the world in the same way they also extended their manufacturing plant all over
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the world. DEMAG has 16 manufacturer plant all over the world. For our south Asia region
DEMAG has established a manufacturer plant in India which is situated Chakan, Pune. The total
area of the factory is 12.7 Acres, office area is 2000 sq. mts and manufacturing facility is 11,300
sq. mts. In this manufacturing plant DEMAG manufacturing especially Metallic portion like
Girder, End Carriage, they are also manufacturing some others components in this plant such as
driving wheel, Hoist Trolley etc. rest of the parts of crane they are importing from German
original plant.
4.3 Crane Design Engineering
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Figure 10: Design View of Crane
Designing DEMAG Crane based on India there is a team of more than 50 design engineers
equipped with design tools like Static calculation, Hoist designer, Drive Designer, Cal drive etc.
these are the engineers are working in the design section and they designing with following
international design standard.
4.4 Girder manufacturing Process
Girder is the most manufactured part of crane in DEMAG India plant. In this plant DEMAG
manufactured maximum 400 Ton capacity girder. They are using several processes in
manufacturing girder.
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Figure 11: Butt welding for all Joints of Girder
In this process this is all joints of Girder is attaching by Butt welding which is being done by
automated process. Here copper plate at bottom ensures no rework for gouging and re-welding.
This process penetration hence stronger joint, and this process giving in longer equipment life.
Figure 12: Inverter Based Speed Pulse Welding
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By Inverter Based Speed Pulse as well as fillet welding the manufacturer provide some particular
strength for all types of crane girder such as ensure good weld penetration, Process followed
ensures higher productivity, Better weld quality ensures load bearing member delivers consistent
performance over the life of equipment.
4.5 Painting and Testing Process of Girder under Manufacture
Figure 13: Crane Girder under manufacture
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Figure 14: Testing Process under Manufacturing
The DEMAG Crane Girder is Consistent, Uniform, Well Treated Surfaces. In DEMAG Crane
manufacturer plant all manufactured parts of Crane are shot blasted and painted in house. These
two things make the Girder and others part of crane gives much more strength. By shot blasting
process the girder surfaces are well prepared it also provide better paints adherence. All this
provide a crane girder long life time.
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4.6 Girder Camber and Wheel Alignment Process
Figure 15: Girder Camber and Wheel Alignment Process
After manufactured and painting a girder next process of girder is wheel alignment, in this
portion Special Theodolite process ensures accuracy in wheel alignment to 0.3 – 0.4 mm as
opposed to conventional piano wire process.
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Figure 16: Girder Alignment with End Carriage
This process followed by only DEMAG as a crane manufacturer. This alignment ensures
complete alignment between girder and end carriage. This perfect alignment achieved through
good design, innovative manufacturing and special fixtures used. This is how Crane ensuring
their high quality of product.
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Girder alignment with End carriage
Chapter Five
Different Parts of DEMAG Crane
5.1 Complete DEMAG Crane Layout View
Figure 17: Complete Crane Layout View
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Main Part of DEMAG Cranes are Girder, Hoist, End Carriage, Long Travel Motor, Cross Travel
motor, Hoisting Motor, Cross Travel trolley. The individual part description is given below:
5.2 Girder
Crane Girder is the main part of crane, with girder all other parts are assembly according to their
alignment. There are two types of girder one is single girder another is Double girder. In single
girder crane Hoist is set up under the girder and in double girder crane hoist is set up between
two girders which is shown in figure of girder. Single girder maximum capacity is 12.5 Ton and
Double girder maximum capacity is 50 Ton.
Figure 18: Crane Girder
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5.3 DEMAG Rope Hoist
Figure 19: Hoist
A complete hoist is consists of Hoist motor, cross travel motor, rope, bottom block wheel and
hook. Hoist motor executes the weight from the floor up to its top edge. Cross travel motor gives
the cross travel motion to the hoist to carry the load to one column to another column. Rope is
aligned with rope guide which is attached with bottom block pulley and hook to lift the load.
With the new DR rope hoist, Demag Cranes & Components has introduced a state-of-the-art
standard for crane applications with loads weighing up to 50 MT and, at the same time, an
entirely new crane philosophy. The C shape of the DEMAG DR rope hoist design is ideally
suited to crane applications. Thanks to the many benefits to offer by the new DR rope hoist, the
entire crane operates much more efficiently.
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Hoist
Hoist Motor
CT Motor
Rope
Bottom Block Wheel
Hook
Proven crane geometry guarantees high design rigidity, optimum travel characteristics
and minimum wear
Raised crane girders, designs tailored to match the roof structure, and compact trolleys
with minimum approach dimensions facilitate larger hook paths as well as better
utilization of the available space and reduce initial construction and subsequent costs
Ergonomic pushbutton stations and interactive radio controls with load range display
ensure highly convenient operation and safe load handling. The display provides
complete transparency of the system controls
Infinitely variable speed control in all motion axes, via frequency inverter-fed drives,
reduces load sway, facilitates exact and gentle positioning, and lowers the mechanical
load on the crane installation
High lifting and cross travel speeds provide faster handling rates and greater efficiency
Standard overload devices prevent unsafe overload conditions
Crane
Benefits with Rope Hoist:
Minimum operating cost thanks to extended FEM 2m+ service life (1900-hour full load
service life) which exceeds the duty requirements of H4 rating per ASTM B30.16
Improved load handling due to increased lifting and cross travel speed
Minimum load-sway thanks to infinitely variable cross travel speeds
System monitoring for improved operational transparency
Improved utilization of your production area thanks to minimum approach dimensions
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5.4 End Carriage
Figure 20: End Carriage
End carriage is the part which is attached with the girder; there is a motor with end carriage
which is called long travel motor. Inside the end carriage there are two wheels by which the
crane runs on the rail of runway beam.
Maximum strength by using a rigid box-section design with reinforced connection areas
as well as machined tolerances in the crane girder connection system guarantee superior
structural integrity and optimum travel characteristics with minimum wear
The precise travel wheel alignment and exact adaptation of the crane span dimension via
interchangeable spacer elements ensure optimum travel characteristics and high
adaptability
End trucks configured with proprietary structural design programs
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5.5 Power Supply Line
Figure 21: Power Supply Line
DEMAG has special power supply line for their crane the specifications of power supply line is
give below:
DEMAG DCL compact conductor line for 4 to 7 poles; connections ensure long-term
power supply and minimize unplanned downtime.
Pre-assembled building blocks for simple assembly or replacement of current collector
trolleys or complete straight sections provide optimum serviceability
IP 23 or IP 24 high protection against accidental contact with sealing lip and integral
expansion joints for optimum safety
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5.6 Travel Unit
Figure 22: Travel Unit
Maintenance-free drives with anti-friction bearings lubricated for life, maximum bearing
centers to accommodate horizontal forces, and travel wheels made of spheroidal graphite
nodular iron provide for favorable travel characteristics and minimum crane runway wear
Infinitely steeples variable travel speeds via frequency inverters with speeds up to 240
fpm guarantee travel with minimum load-sway as well as precise positioning
5.7 Control System
Figure 23: Control System of Crane
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DEMAG has three types of control system for their crane such as push button pendent with
cable, radio control pendent and Cabin Control System.
Ergonomically designed control units for safe, fatigue-free handling. The display provides
complete transparency for control of the installation. The CAN Bus control system corresponds
to safety category 3 to DIN / EN 954.
DEMAG DSE pushbutton control pendant suspended for separate travel on the crane girder.
Handheld or belly box CAN Bus radios for wireless control allow operator flexibility.
5.8 Bottom Hook
Figure 24: Bottom Hook
Enhanced bottom block design with standard load hook for ease of load connection
Rope lead-in guard eliminates the risk of being caught between the rope and sheave
Handle recesses on both sides simplify handling of the bottom block and increase
operating safety
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5.9 DEMAG Chain Hoist
Figure 25: DEMAG Chain Hoist
DEMAG Chain hoist which is used as a components to lifting lower weight load it can carry
maximum 3 ton capacity weight. Chain hoist is also cheap prices hoist in comparing with Rope
hoist. In terms of Chain Hoist it require less maintenance that is why when there is a less weight
load require to lift DEMAG cranes suggest to customer to purchase DEMAG Chain Hoist.
DEMAG Chain Hoist is denoted by DC-Com which is proven simple and highly reliable. DC-
Com units can be integrated into the rail of KBK modular system or installed on I beam of the
girders.
Advantages of DC-Com Hoist:
Simple Commissioning
Ergonomic Handling
Service Friendly
FEM Classification 1 AM and 2 M
24 Contractor Control
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5.10 Hoist Motor Description
42
Suspension Bracket
Gear Box
Housing
Hoist Motor
Chain Drive
Brake
Bottom Block
Figure 26: Hoist Motor Description
Details Description of Hoist Motor:
1. Gear Box:
Figure 27: Gearbox of Crane Hoist
A Gearbox is a mechanical way to transfer energy from one device to another device. In
DEMAG crane hoist there is using most modern gearbox to increase torque while reducing the
speed. The gear train is built up on three shafts. The input shaft extends from the front of the
transmission. An external parallel-splined section engages with internal splines on the clutch-
driven plate. A main-drive gear is an integral part of the shaft. It meshes constantly with a mating
gear on a counter-shaft which has a number of gears formed on it. These gears mesh with mating
gears on the main shaft, or output. These main shaft gears are supported on bearings on the shaft.
They can rotate without turning the output. Each main shaft gear has an external toothed section
on one side. The teeth face an internally-toothed engagement sleeve located on a central hub,
which is itself splined to the main shaft. The engagement sleeve can slide in either direction to
engage the external teeth on the appropriate gear. This locks the gear through the sleeve and hub,
to the main shaft. Before engagement of the components occurs, a synchromesh device between
43
the sleeve and gear synchronizes them. The gears constantly in mesh have their teeth cut on a
helix, at an angle to the gear center line. This reduces gear noise and distributes load more
evenly, as several teeth are in contact at any one time. The engagement sleeve moves to engage
the dog teeth of the relevant gear when a gear is selected. This locks the gear to the shaft, so
drive can be transmitted. Teeth on the reverse idler are normally straight cut or spur gears, cut
parallel to the gear center line. When reverse is selected, this connects the reverse idler with
mating gears on the countershaft and main shaft. The reverse idler rotates on a plain shaft fixed
in the casing. It transfers the drive from one shaft to the other, and reverses the direction of
rotation of the main shaft. DEMAG provides free Maintenance of their Gear box up to 10 years.
With classify action in FEM Group of Mechanisms DEMAG 2m+; the DC-Pro sets a new
standard with a rated Service life of 1900 hours at full load. In practical terms, this means the
service life is extended by approx. 20 %. The helical gearing of all gearbox stages also reduces
operating noise and provides for smooth operation.
Types of Gearbox:
Sliding Mesh Gear Box
Constant Mesh Gear Box
Synchromesh Gearbox
Planetary Gear Box or Epicyclical gear box
Automatic Transmission Hydromantic Gear Box
2. Brake – A brake is device for slowing or stopping motion as of a vehicle specially
contact friction. Brake is something which makes the running part in lower speed
position. Brakes are very much essential to safely operating motor. Without the ability of
making slow and stop a running parts we cannot work, which is also applicable for
Crane. In crane there are 6 motor is existing 4 motors for long travel motion and 1 motor
for cross travel motion and another motor is for lift the weight. In the existing brake of
DEMAG crane the manufacturer gives maintenance-free for up to 10 years (sizes DC 10
– 25 up to 5 years). Thanks to minimum wear, adjustment is not necessary; short and
gentle run-on path. The brake enclosure features double encapsulation and is therefore
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impervious to poor weather and operating conditions. In this cases there is not very much
require for brake maintenance for customer.
3. Slipping clutch
Figure 28: Design of Slipping Clutch
Slipping Clutch is commonly used in crane motor to protect against overload. In DEMAG
Cranes the manufacturer gives maintenance-free for up to 10 years. Integrated behind the brake
in the power drive, it provides reliable protection against extreme overload. Damaging
permanent slipping is not possible thanks to integrated speed monitoring.
A slipping clutch consists of two assemblies a cartridge and housing. The cartridge is a set
screwed or keyed to the input shaft. The housing may be either set screwed or keyed to the
output shaft. It also can be attached to the output gear or pulley.
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4. Height adjustment of the control pendant – The length of the control cable and, therefore,
the suspension height of the control pendant can be infinitely varied for a hook path range of 2 –
5 m and 5 – 8 m. The length of control cable that is not required is accommodated under the
service cover. The control cable is rated for electric travel applications in 3 axes.
5. Control – with 24 V contactor control, operating limit switches (upper/lower) and elapsed
operating time counter as standard. A geared limit switch with four contacts for fast-to-slow and
limit cut-off is used as the operating limit switch for sizes DC 16 and 25.
6. Round steel chain – a special DEMAG chain of high-strength, ageing-resistant material with
high surface hardness. Galvanization and additional surface-treated to protect against hostile
environments.
7. Suspension bracket –
Figure 29: Suspension Bracket
DC-Pro chain hoists are suspended in pendulum fashion and make optimum use of the available
height thanks to their small C headroom dimension. DC-Pro units are supplied with short and
long suspension brackets as standard and can always be attached to the superstructure with the
optimum connection.
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8. Housing –
Figure 30: Housing
9. Hoist motor – robust and enduring high-performance motor with large safety reserves even at
high ambient temperatures and in prolonged operation. 2 hoist speeds with F4 ratio as standard.
(Insulation class F, 360 s/h and 60 % CDF)
10. Chain drive –
Figure 31: Chain Drive
Chain drive is the way transmitting mechanical power from one place to another place. The plug-
in unit facilitates quick and easy replacement of the entire chain drive without having to remove
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the motor or gear parts. Downtimes can therefore be cut significantly. The chain drive consists of
highly wear-resistant materials for a long service life.
11. Chain collector box – attached in pendulum fashion, made of tough, flexible and
particularly impact resistant plastic; capacity for up to 8 m hook path. Chain collector bag for
chain lengths up to 40 m as well as special lengths up to 120 m can be supplied.
12. Bottom block –
Figure 32: Bottom Block
In DEMAG Crane a Hook is attached with Bottom Block by which crane can take weight. In
DEMAG Crane up to 1000 kg with single chain fall for improved ergonomic handling of the
hook with fittings. Chain wear is simultaneously reduced, since no chain return arrangement is
required. The new, compact and particularly ergonomic DC bottom block is used for 2/1 reeving
arrangements. The cut-off springs required for the limit switches are integrated inside the bottom
block and therefore save 60 mm of the valuable C dimension.
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Chapter Six
SERVICE &
Maintenance
6.1 DEMAG SERVICE
DEMAG providing their service all over the world by their expert service team with 220 service
stations. Besides services DEMAG also supply rapid spare parts according to customer
requirement. DEMAG providing service training to their engineer as well as they are training to
their entire dealer service engineers. Highly qualified and trained staff for maximum service
quality. DEMAG service consultants support you with a wide range of industry-specific
expertise to create a service strategy individually tailored to your business needs. DEMAG
Services engineers are extensively trained and receive continuous further development to
maintain their professional edge. The result is extremely high-quality service support from a
single source Local presence all over the world. DEMAG service organization is represented all
over the world, with more than 2,200 service engineers supported by a highly reliable spare parts
logistics system. All of the services DEMAG provides are specially designed to meet the needs
of the industrial crane sector to achieve the maximum efficiency of your equipment. This also
includes a comprehensive training program. Customer can decide for themselves how much
service they want to have, and also whether they opt for ad-hoc service work to be provided as
required or longer-term service packages. Our service covers the entire product life cycle.
Greenland Technologies Limited also has three Service engineers for DEMAG crane service in
Bangladesh. Those engineers have trained from DEMAG Indian plant.
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6.2 DEMAG Spare Parts Quality:
Long service life
Gearbox, brake and slipping clutch are maintenance-free for up to 10 years (DC-Pro 10–25 brake for up to 5 years)
Low-wear brake thanks to regenerative braking Brake adjustment is not necessary No load dropping due to slipping clutch engineered in front of the brake in the load-
bearing arrangement Reduced chain wear thanks to 1/1 reeving for loads up to 2,200 lbs. (1,000 kg) Robust cylindrical-rotor motor with fan and separate DC brake No brake bonding thanks to double encapsulated brake
High operating reliability
Standard requirements satisfied for functional safety
No continuous slipping thanks to slipping clutch with automatic cut-out
24 V contactor control with internal “tri-state” signal transfer
Chain hoist and travel drive feature IP 55 enclosure, insulation class F
Automatic braking if the control system fails
Service-friendly
"Plug & Lift" and "Plug & Drive" for all electrical connections
Elapsed operating time counter, status and error messages shown on display
Service cover for rapid access to plug connections, strain relief arrangements,
collector for 10 ft (3 m) control cable and chain drive
Chain lubrication through lubrication opening in the chain guide for improved lubrication
between links (sizes DC 1–10)
Reduced downtimes as chain drive can be replaced without dismantling motor or gearbox
parts.
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DEMAG Innovative technical features for meeting demanding operating requirements
high number of starts/stops and high duty factor due to mechanical microspeed and
conical-rotor brake motors; also for high ambient temperatures
highly precise positioning with mechanical microspeed
three sizes with load capacities up to 100 tons
Hook path up to 341 ft.
numerous rope drum designs available: one, two, four, six and eight grooves
limit positions reliably monitored by precision limit switches that are directly driven by
the drum
proven contactor control for reliable operation in arduous environments
space-saving planetary gearbox arrangement: protected inside the drum
High safety levels and long service life due to effective load distribution in the planetary
gearbox.
Simple integration into any design:
rope lead-off possible in any direction
torsion ally rigid frame open on all sides – for bolted connection on all sides
basic hoist with electrical enclosure; optionally with or without electrical equipment
rope reeving arrangement configured to meet specific technical requirements large range
of standard lifting speeds
6.3 Service Activities of Greenland Technologies Limited
PDI ( Pre Delivery Inspection )
Free Services
Warranty Services
Paid Services
Special Services
On call Service
Spare Parts Supply
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Greenland Technologies Limited has accomplished some services of DEMAG Crane
1. Siemens Bangladesh Limited
2. Summit Power Comilla Plant
3. Bangla Trac Limited
4. ABB Limited
5. Summit Power Maona Plant
6. Abul Khair Steel Products Limited
Siemens Bangladesh Limited: In madartak plant of Siemens Bangladesh Limited there
is an existing DEMAG crane which capacity is 4 Ton, they use this crane to moving their
power plant machine for maintenance. But the crane was having problem and they called
Engineer of Greenland Technologies limited for their DEMAG crane service. After
reaching their plant they have checked the crane various part after checking they have
found the crane has problem in crane control panel & also in inverter. They have also
found a problem in Control Pendent switch of Cross travel motion. In control panel there
was some IC damaged and the Inverter also has some IGBT Problem. The engineers
worked on those panel and inverter. They replaced the damaged IC of Control panel and
IGBT of Inverter after that repair work, this two spare was set up with the crane in their
plant and then crane was running. For cross travel switch of Control Pendent the
engineers were suggest that it should be replaced by new control pendent and after the
engineers suggestion the Siemens authority was purchased the pendent.
Bangla Trac Limited: In bangla trac limited they have two cranes one is 25 Ton
capacity Double Girder crane another is 10 Ton Single Girder Crane. In their 25 ton crane
they were facing some Mechanical problem. The Crane long travel and cross travel motor
brake was not working properly. And Pendent cable has some problem such as it doesn’t
run freely. After working on brake of Long Travel and Cross travel, the brake was
working. The brake attachment with the liner was not properly fitted that is why brake
was not working well. After service it is now okay. In their 10 Ton Crane there was a
problem in runway rail and crane travelling wheel. When crane travel on runway rail it is
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make a big sound then the customer claim to Greenland Technologies Limited to
overcome this problem. The engineers reach the places and they found that is not
lubricants and the wheel was getting so much friction with runway rail that is why the
sound was making. There was used lubricants on runway rail and DEMAG Crane wheel
for smooth running and after that the crane is running properly.
In other service issues Summit Power Comilla, Maona, ABB Limited and Abul Khair Steel
Products Limited, they were using their crane for long time and their fast moving spare parts
were totally damaged. After getting the suggestion from Greenland Technologies Engineers they
were placed order for those spare parts.
In DEMAG Crane there is some often services require for Gearbox, Bottom Block Pulley, End
Carriage wheel, Long Travel Motor, Cross Travel Motor, Lifting Motor, Rope Guide, Chain
Drive, Brake of all Motor, Travel Trolley of Hoist, Control Panel, Inverter.
Some DEMAG Crane Service Scenario in Bangladesh along Greenland Technologies Limited
Engineers:
Caption: Siemens Bangladesh Limited Madartak Plant
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Caption: Siemens Bangladesh Limited Madartak Plant
Caption: Ashuganj Power Plant Caption: Repairing Crane Spare Parts in
Greenland Technologies Workshop.
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6.4 DEMAG Crane Installation in Bangladesh
Recently in Bangladesh there are four DEMAG Crane installed. Those cranes are in different
capacities and different dimensions. Those crane installed in Megna Power Plant Limited,
Khulna Power Plant Limited, Ashuganj Power Plant Limited and Bargen Engine Bangladesh
Limited. In Meghna Power Plant Limited installed Crane capacity is 3.2 Ton, Khulna Power
Company Limited and Bargen Engine Bangladesh Limited also installed 3.2 Ton Capacity crane.
In Ashuganj Power Plant Limited they have installed a 400 Ton capacity crane which is world
largest capacity DEMAG made crane. All those crane was manufactured in DEMAG Cranes
Indian Manufacturer Plant.
For installing DEMAG Crane a Mobile crane is require to lift the crane above the Beam. Before
lifting the crane there is require to set the runway beam or granty Girder which is placed on
Column core bell. On the core bell there is require a steel plate along with bolt. The granty girder
will be fixed by welding with the steel plate and bolt which was placed on core bell. After setting
the granty girder, on the granty girder there will be a rectangular bar which is called runway rail
that will be placed. Then the crane girder will require lifting above the granty girder, after crane
girder reaching above then the End Carriages required to attach with crane girder. After setting
the End Carriage with the girder crane is stable on above of the Beam. Then gradually all others
parts of crane installed such as crane hoist, long travel motor, cross travel motor, Host Trolley,
festoon with cable, contractor of Control Pendent, Control Panel, inverter, power cable trolley
etc. after set up all the parts then the engineers work on power supply. In installing crane the
alignment is most important thing, such as Granty girder, Runway rail, Crane girder. All this
parts should place with right alignment otherwise crane will not work properly.
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Caption: Khulna Power Company Limited Purchased New Crane Girder
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6.5 Existing DEMAG Crane in Bangladesh
In Bangladesh more than 80 DEMAG Cranes existing in different industrial sector. The existing
DEMAG Crane list in Bangladesh given below:
Ashuganj Combined Cycle Power Plant
BSRM
Abul Khair
PHP
KSRM
Summit Power
Siemens Limited
Bangla CAT
Orien Group
Khulna Power
Rolls Royce
Everest Power
Unique Cement
Khulna Shipyard
Bargen Engine Bangladesh Limited
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Maintenance
6.6 Definition of Maintenance
58
Maintenance is a set of organised activities that are carried out in order to keep an item
in its best Operational condition with minimum cost acquired. The combination of all
technical and administrative actions, including supervision actions, intended to retain an
item in, or restore it to, a state in which it can perform a required function.
6.7 Maintenance Activities
Activities of maintenance function could be either repair or replacement activities, which
are necessary for an item to reach its acceptable productivity condition or these
activities, should be carried out with a minimum possible cost.
6.8 Maintenance History
1. In the period of pre-World War II, people thought of maintenance as an added
cost to the
2. Plant which did not increase the value of finished product.
Therefore, the maintenance at that era was restricted to fixing the unit when it
breaks, because it was the cheapest alternative.
3. During and after World War II at the time when the advances of engineering and
scientific technology developed, people developed other types of maintenance,
which were much cheaper such as preventive maintenance. In addition, people
in this era classified maintenance as a function of the production system.
4. Now a day, increased awareness of such issues as environment safety, quality of
product and services makes maintenance one of the most important functions
that contribute to the success of the industry. World-class companies are in
continuous need of a very well organised maintenance programme to compete
world-wide.
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6.9 Maintenance Objectives
Maintenance objectives should be consistent with and subordinate to production goals.
The relation between maintenance objectives and production goals is reflected in the
action of keeping production machines and facilities in the best possible condition.
Maximising production or increasing facilities availability at the lowest cost and at
the highest quality and safety standards.
Reducing breakdowns and emergency shutdowns.
Optimising resources utilisation.
Reducing downtime.
Improving spares stock control.
Improving equipment efficiency and reducing scrap rate.
Minimising energy usage.
Optimising the useful life of equipment.
Providing reliable cost and budgetary control.
6.10 Types of Maintenance
Run to Failure Maintenance (RTF)
Preventive Maintenance (PM)
Corrective Maintenance (CM)
Improvement Maintenance (IM)
Predictive Maintenance (PDM)
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6.10.1 Run to Failure Maintenance (RTF)
The required repair, replacement, or restore action performed on a machine or a
facility after the occurrence of a failure in order to bring this machine or facility to
at least its minimum acceptable condition.
It is the oldest type of maintenance.
It is subdivided into two types:
Emergency maintenance: it is carried out as fast as possible in order to bring a failed
machine or facility to a safe and operationally efficient condition.
Breakdown maintenance: It is performed after the occurrence of an advanced
considered failure for which advanced provision has been made in the form of repair
method, spares, materials, labour and equipment.
6.10.2 Preventive Maintenance (PM)
It is a set of activities that are performed on plant equipment, machinery, and systems
before the occurrence of a failure in order to protect them and to prevent or eliminate
any degradation in their operating conditions. The maintenance carried out at
predetermined intervals or according to prescribed criteria and intended to reduce the
probability of failure or the degradation of the functioning and the effects limited
Routine maintenance which includes those maintenance activities that is
repetitive and periodic in nature such as lubrication, cleaning, and small
adjustment.
Running maintenance which includes those maintenance activities that are
carried out while the machine or equipment is running and they represent those
activities that are performed before the actual preventive maintenance activities
take place.
Opportunity maintenance which is a set of maintenance activities that are
performed on a machine or a facility when an unplanned opportunity exists
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during the period of performing planned maintenance activities to other machines
or facilities.
Window maintenance which is a set of activities that are carried out when a
machine or equipment is not required for a definite period of time.
Shutdown preventive maintenance, which is a set of preventive maintenance
activities that are carried out when the production line is in total stoppage
situation.
6.10.3 Corrective Maintenance (CM)
In this type, actions such as repair, replacement, or restore will be carried out after the
occurrence of a failure in order to eliminate the source of this failure or reduce the
frequency of its occurrence. The maintenance carried out after recognition and intended
to put an item into a state in which it can perform a required function.
6.10.4 Improvement Maintenance (IM)
Improvement maintenance is more particularly three types those are given below:
Design-out maintenance which is a set of activities that are used to eliminate
the cause of maintenance, simplify maintenance tasks, or raise machine
performance from the maintenance point of view by redesigning those machines
and facilities which are vulnerable to frequent occurrence of failure and their long
term repair or replacement cost is very expensive.
Engineering a service which includes construction and construction
modification, removal and installation, and rearrangement of facilities.
Shutdown improvement maintenance, which is a set of improvement
maintenance activities that are performed while the production line is in a
complete stoppage situation.
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6.10.5 Predictive Maintenance (PDM)
Predictive maintenance is mainly two types those are given below:
Condition-based predictive maintenance depends on continuous or periodic
condition monitoring equipment to detect the signs of failure.
Statistical-based predictive maintenance depends on statistical data from the
meticulous recording of the stoppages of the in-plant items and components in
order to develop models for predicting failures.
Among all the maintenance DEMAG is doing very strongly preventive and Improvement
maintenance. For preventive maintenance DEMAG keeping a contract with the
customer that annual maintenance contract. And for improvement maintenance DEMAG
is very much fast and effective. DEMAG service engineer always doing work for crane
modernization and up gradation of DEMAG crane also others brand crane. For up
gradation first of all DEMAG engineer doing a PCA- Professional Crane Audit, by which
they determine how to work for up gradation of the particular crane. In Bangladesh
DEMAG Service engineer already work for crane up gradation they work a crane of
Biman Bangladesh Limited. They have a DEMAG Crane which was installed on 1975,
and the crane capacity was 5 Ton but it could not take load of 5 Ton by up gradation
now the crane can take load of 5 Ton. DEMAG also has offer for up gradation of 4
Crane of Khulna Shipyard.
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Chapter SevenRecommendation
& Conclusion
Recommendation
During the practicum period it was seemed to us that some necessary steps can be taken to
develop the working procedures
Greenland Technologies Limited should increase their Service Engineers.
Greenland Technologies Limited should be more active regarding maintenance work.
Skilled and dedicated team need to monitor all the activities.
Proper handling the Annual maintenance Contract.
Using fully computerized control system for better Service.
Positive work environment and helpful manpower.
Need to increase skillful and enthusiastic technician & engineer.
Spare parts need to available for providing in emergency of Customer.
Use more safety device to remove accident.
It is important to ensure the companies transportation advantage.
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Conclusion
It was a great time with Greenland Technologies Limited in my practicum period. I had some
excellent time with their engineer and also some DEMAG Engineers Mr. Manish kapoor, Mr.
Kishanu, Mr. Shivaratna, Mr. Ashwin Gandy, Mr. Rana Saha. Those peoples I meted during my
practicum each and every one was very cordial and helpful to me. I have learned those thing that
how I can start thinking about problem. The DEMAG Engineers were very much interested in
team work I was also one of them, but due to limitation of a practicum student and other safety
issue I could not participate with them in every service work which was done in the time of my
practicum.
Bibliography
Most of the data and information has been collected from the DEMAG and Greenland
Engineers.
Rest of the information is collected from company website, manual and internet.
Industrial unit management handbook
Servicing manual handbook
http://en.wikipedia.org
www.google.com
www.getco.com.bd
www.demagcranes.com
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