Challenges and Safety in Erection and Commissioning of 280/85 Tons Single Failure Proof EOT Crane at PFBR

Swamynathan Kudiyarasan; Poundraj Sivakumar; Sanjeevi Umapathi; Malangu Eswaran Sarath Chander

doi:doi:10.11648/j.ajset.20190404.12

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Challenges and Safety in Erection and Commissioning of 280/85 Tons Single Failure Proof EOT Crane at PFBR

Swamynathan Kudiyarasan, Poundraj Sivakumar, Sanjeevi Umapathi, Malangu Eswaran Sarath Chander

Published in American Journal of Science, Engineering and Technology (Volume 4, Issue 4)

Received: 26 September 2019 Accepted: 26 November 2019 Published: 10 December 2019

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Abstract

The Electric overhead traveling (EOT) crane installed in Prototype Fast Breeder Reactor (PFBR), Reactor Containment Building (RCB) is the largest capacity EOT crane installed in any nuclear power plants in India with some unique features of its own. It has been built with a single failure proof concept which is one of the prime requirements of a nuclear facility as per the standards of NUREG/IS. It is a double bridge girder type; the girder used in this crane is a single structure having a length of 34.8m without any joints as designed by IGCAR/BHAVINI (first of its kind). The span of the EOT crane is 33.4m and installed at a height of 42m from the ground level with the lifting height of 42.5m. This crane was manufactured by an Indian company M/s. UNIQUE CRANE, NASIK. Two hooks (280 tons / 85 tons) are connected in the same trolley sharing the Long Travel (LT). Load testing of the complete crane was done at factory before transporting it to PFBR site. The components of the crane were assembled in PFBR site. The erection methodology adopted was distinct w. r. t the site condition, as the components which were handled were very heavy, available space for installation was restricted and the head room was also very less. This erection has been completed successfully and very safely without any notable incidents. This activity is a biggest achievement / milestone in the nuclear industry in India. Later the EOT crane was commissioned, load tested with 350 tons load (negligible deflection) and being operated successfully without any incidents so far. This was achieved by accurate erection procedure, stringent Quality Assurance Plan (QAP), Job Hazard Analysis (JHA) and Safe Operation Procedure (SOP). Many challenges were faced during manufacturing, testing, erection and load testing at site. This paper deliberates those challenges.

Published in	American Journal of Science, Engineering and Technology (Volume 4, Issue 4)
DOI	10.11648/j.ajset.20190404.12
Page(s)	66-72
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2019. Published by Science Publishing Group

Keywords

EOT Crane, Single Failure Proof, Bridge Girder, Bogie, Safety, Nuclear Industry, Erection

References

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[2]	Dong Hun Lee, Sang Jin Kim, Man Seung Lee, Jeom Kee Paik (2019). Ultimate limit state based design versus allowable working stress based design for box girder crane structures. Thin-Walled Structures 134 (2019) 491–507.
[3]	Omkar K. Sakurikar, D. V. Kushare (2016), Review of Overhead Crane and Analysis of Components Depending on Span, IRJET, Volume: 03 Issue: 05 \| May-2016 pp 1004-1008.
[4]	M. Gohil, “Optimum Design of Bridge Girder of an EOT Crane Structure”, Institute of Technology, Nirma University, Ahmedbad-382481, 25-27, November 2009.
[5]	Patel Khalidurfeasif, Deepali Bharti (2015). Finite Element Analysis Of 450T EOT Crane Box Girder, International Journal of Advance Engineering and Research Development Volume 2, Issue 11, November -2015 pp 171-178.
[6]	Gianni Niccolini, Giuseppe Lacidogna, Alberto Carpinteri (2019). Fracture precursors in a working girder crane: AE natural-time and b-value time series analyses. Engineering Fracture Mechanics 210 (2019) pp 393–399.
[7]	Abhinay Suratkar, Vishal Shukla, Dr. K. S. Zakiuddin (2013). Design Optimization Of Overhead EOT Crane Box Girder Using Finite Element Analysis, International Journal of Engineering Research & Technology (IJERT), Vol. 2 Issue 7, July – 2013.
[8]	Dhaval H. Kanjariya (2015), A Review on Design and Analysis of Hoisting Machinery in EOT Crane, IJSRD - International Journal for Scientific Research & Development\| Vol. 3, Issue 02, 2015.
[9]	Mr. Swapnil K. Agrawal, Mr. Vaibhav H. Bankar (2016), Design of Components used in Hoisting Mechanism of an EOT Crane: A Critical Literature Review, International Journal of Engineering Technology, Management and Applied Sciences, December 2016, Volume 4, Issue 12.
[10]	Leszek Sowa, Zbigniew Saternus, Marcin Kubiak (2017), Numerical modelling of mechanical phenomena in the gantry crane beam, XXI International Polish-Slovak Conference “Machine Modeling and Simulations 2016”. Procedia Engineering 177 (2017) pp 225 – 232.
[11]	Vinay Dubey, Rajiv Premi, (2016). Hazard Identification of cranes and their control measures, © 2016 IJEDR \| Volume 4, Issue 1 pp 504-509.
[12]	Vinay Dubey, Praveen Patel (2015). hazard identification and their control in lifting machinery. Int. J. of Engg. Sci. & Mgmt. (IJESM), Vol. 5, Issue 2: April-June: 2015, 1-4.
[13]	Stian Ruud, Age Mikkelsen,” Risk-based rules for crane safety systems”, Reliability Engineering and System Safety 93 (2008) 1369–1376.
[14]	Zhiping Chen, Zhewei Li, Chaoliang Huang, Guoan Zhang, Huanwei Yu,” Safety Assessment Method of Bridge Crane Based on Cluster Analysis and Neural Network”, Procedia Computer Science 131 (2018) 477–484.
[15]	Maria Francesca Milazzo, Giuseppa Ancione, Vesna Spasojevic Brkic (2015), safety in crane operations: an overview on crane-related accidents, 6th international Symposium on Industrial Engineering, SIE Serbia, September 2015.

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Swamynathan Kudiyarasan, Poundraj Sivakumar, Sanjeevi Umapathi, Malangu Eswaran Sarath Chander. (2019). Challenges and Safety in Erection and Commissioning of 280/85 Tons Single Failure Proof EOT Crane at PFBR. American Journal of Science, Engineering and Technology, 4(4), 66-72. https://doi.org/10.11648/j.ajset.20190404.12

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ACS Style

Swamynathan Kudiyarasan; Poundraj Sivakumar; Sanjeevi Umapathi; Malangu Eswaran Sarath Chander. Challenges and Safety in Erection and Commissioning of 280/85 Tons Single Failure Proof EOT Crane at PFBR. Am. J. Sci. Eng. Technol. 2019, 4(4), 66-72. doi: 10.11648/j.ajset.20190404.12

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AMA Style

Swamynathan Kudiyarasan, Poundraj Sivakumar, Sanjeevi Umapathi, Malangu Eswaran Sarath Chander. Challenges and Safety in Erection and Commissioning of 280/85 Tons Single Failure Proof EOT Crane at PFBR. Am J Sci Eng Technol. 2019;4(4):66-72. doi: 10.11648/j.ajset.20190404.12

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@article{10.11648/j.ajset.20190404.12,
  author = {Swamynathan Kudiyarasan and Poundraj Sivakumar and Sanjeevi Umapathi and Malangu Eswaran Sarath Chander},
  title = {Challenges and Safety in Erection and Commissioning of 280/85 Tons Single Failure Proof EOT Crane at PFBR},
  journal = {American Journal of Science, Engineering and Technology},
  volume = {4},
  number = {4},
  pages = {66-72},
  doi = {10.11648/j.ajset.20190404.12},
  url = {https://doi.org/10.11648/j.ajset.20190404.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ajset.20190404.12},
  abstract = {The Electric overhead traveling (EOT) crane installed in Prototype Fast Breeder Reactor (PFBR), Reactor Containment Building (RCB) is the largest capacity EOT crane installed in any nuclear power plants in India with some unique features of its own. It has been built with a single failure proof concept which is one of the prime requirements of a nuclear facility as per the standards of NUREG/IS. It is a double bridge girder type; the girder used in this crane is a single structure having a length of 34.8m without any joints as designed by IGCAR/BHAVINI (first of its kind). The span of the EOT crane is 33.4m and installed at a height of 42m from the ground level with the lifting height of 42.5m. This crane was manufactured by an Indian company M/s. UNIQUE CRANE, NASIK. Two hooks (280 tons / 85 tons) are connected in the same trolley sharing the Long Travel (LT). Load testing of the complete crane was done at factory before transporting it to PFBR site. The components of the crane were assembled in PFBR site. The erection methodology adopted was distinct w. r. t the site condition, as the components which were handled were very heavy, available space for installation was restricted and the head room was also very less. This erection has been completed successfully and very safely without any notable incidents. This activity is a biggest achievement / milestone in the nuclear industry in India. Later the EOT crane was commissioned, load tested with 350 tons load (negligible deflection) and being operated successfully without any incidents so far. This was achieved by accurate erection procedure, stringent Quality Assurance Plan (QAP), Job Hazard Analysis (JHA) and Safe Operation Procedure (SOP). Many challenges were faced during manufacturing, testing, erection and load testing at site. This paper deliberates those challenges.},
 year = {2019}
}

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TY - JOUR
T1 - Challenges and Safety in Erection and Commissioning of 280/85 Tons Single Failure Proof EOT Crane at PFBR
AU - Swamynathan Kudiyarasan
AU - Poundraj Sivakumar
AU - Sanjeevi Umapathi
AU - Malangu Eswaran Sarath Chander
Y1 - 2019/12/10
PY - 2019
N1 - https://doi.org/10.11648/j.ajset.20190404.12
DO - 10.11648/j.ajset.20190404.12
T2 - American Journal of Science, Engineering and Technology
JF - American Journal of Science, Engineering and Technology
JO - American Journal of Science, Engineering and Technology
SP - 66
EP - 72
PB - Science Publishing Group
SN - 2578-8353
UR - https://doi.org/10.11648/j.ajset.20190404.12
AB - The Electric overhead traveling (EOT) crane installed in Prototype Fast Breeder Reactor (PFBR), Reactor Containment Building (RCB) is the largest capacity EOT crane installed in any nuclear power plants in India with some unique features of its own. It has been built with a single failure proof concept which is one of the prime requirements of a nuclear facility as per the standards of NUREG/IS. It is a double bridge girder type; the girder used in this crane is a single structure having a length of 34.8m without any joints as designed by IGCAR/BHAVINI (first of its kind). The span of the EOT crane is 33.4m and installed at a height of 42m from the ground level with the lifting height of 42.5m. This crane was manufactured by an Indian company M/s. UNIQUE CRANE, NASIK. Two hooks (280 tons / 85 tons) are connected in the same trolley sharing the Long Travel (LT). Load testing of the complete crane was done at factory before transporting it to PFBR site. The components of the crane were assembled in PFBR site. The erection methodology adopted was distinct w. r. t the site condition, as the components which were handled were very heavy, available space for installation was restricted and the head room was also very less. This erection has been completed successfully and very safely without any notable incidents. This activity is a biggest achievement / milestone in the nuclear industry in India. Later the EOT crane was commissioned, load tested with 350 tons load (negligible deflection) and being operated successfully without any incidents so far. This was achieved by accurate erection procedure, stringent Quality Assurance Plan (QAP), Job Hazard Analysis (JHA) and Safe Operation Procedure (SOP). Many challenges were faced during manufacturing, testing, erection and load testing at site. This paper deliberates those challenges.
VL - 4
IS - 4
ER -

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Author Information

Swamynathan Kudiyarasan

Department of Atomic Energy, Fast Breeder Reactor, Bharatiya Nabhikiya Vidyut Nigam Limited, Kalpakkam, India
Poundraj Sivakumar

Department of Atomic Energy, Fast Breeder Reactor, Bharatiya Nabhikiya Vidyut Nigam Limited, Kalpakkam, India
Sanjeevi Umapathi

Department of Atomic Energy, Fast Breeder Reactor, Bharatiya Nabhikiya Vidyut Nigam Limited, Kalpakkam, India
Malangu Eswaran Sarath Chander

Unique Industrial Handlers Private Limited, Nashik, Maharashtra, India

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APA Style

Swamynathan Kudiyarasan, Poundraj Sivakumar, Sanjeevi Umapathi, Malangu Eswaran Sarath Chander. (2019). Challenges and Safety in Erection and Commissioning of 280/85 Tons Single Failure Proof EOT Crane at PFBR. American Journal of Science, Engineering and Technology, 4(4), 66-72. https://doi.org/10.11648/j.ajset.20190404.12

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ACS Style

Swamynathan Kudiyarasan; Poundraj Sivakumar; Sanjeevi Umapathi; Malangu Eswaran Sarath Chander. Challenges and Safety in Erection and Commissioning of 280/85 Tons Single Failure Proof EOT Crane at PFBR. Am. J. Sci. Eng. Technol. 2019, 4(4), 66-72. doi: 10.11648/j.ajset.20190404.12

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AMA Style

Swamynathan Kudiyarasan, Poundraj Sivakumar, Sanjeevi Umapathi, Malangu Eswaran Sarath Chander. Challenges and Safety in Erection and Commissioning of 280/85 Tons Single Failure Proof EOT Crane at PFBR. Am J Sci Eng Technol. 2019;4(4):66-72. doi: 10.11648/j.ajset.20190404.12

Copy | Download

@article{10.11648/j.ajset.20190404.12,
  author = {Swamynathan Kudiyarasan and Poundraj Sivakumar and Sanjeevi Umapathi and Malangu Eswaran Sarath Chander},
  title = {Challenges and Safety in Erection and Commissioning of 280/85 Tons Single Failure Proof EOT Crane at PFBR},
  journal = {American Journal of Science, Engineering and Technology},
  volume = {4},
  number = {4},
  pages = {66-72},
  doi = {10.11648/j.ajset.20190404.12},
  url = {https://doi.org/10.11648/j.ajset.20190404.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ajset.20190404.12},
  abstract = {The Electric overhead traveling (EOT) crane installed in Prototype Fast Breeder Reactor (PFBR), Reactor Containment Building (RCB) is the largest capacity EOT crane installed in any nuclear power plants in India with some unique features of its own. It has been built with a single failure proof concept which is one of the prime requirements of a nuclear facility as per the standards of NUREG/IS. It is a double bridge girder type; the girder used in this crane is a single structure having a length of 34.8m without any joints as designed by IGCAR/BHAVINI (first of its kind). The span of the EOT crane is 33.4m and installed at a height of 42m from the ground level with the lifting height of 42.5m. This crane was manufactured by an Indian company M/s. UNIQUE CRANE, NASIK. Two hooks (280 tons / 85 tons) are connected in the same trolley sharing the Long Travel (LT). Load testing of the complete crane was done at factory before transporting it to PFBR site. The components of the crane were assembled in PFBR site. The erection methodology adopted was distinct w. r. t the site condition, as the components which were handled were very heavy, available space for installation was restricted and the head room was also very less. This erection has been completed successfully and very safely without any notable incidents. This activity is a biggest achievement / milestone in the nuclear industry in India. Later the EOT crane was commissioned, load tested with 350 tons load (negligible deflection) and being operated successfully without any incidents so far. This was achieved by accurate erection procedure, stringent Quality Assurance Plan (QAP), Job Hazard Analysis (JHA) and Safe Operation Procedure (SOP). Many challenges were faced during manufacturing, testing, erection and load testing at site. This paper deliberates those challenges.},
 year = {2019}
}

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