Project ID: 296217

INTERNSHIP AT

TOP CRANE PVT. LTD. PIPLANA,RAJKOT

A PROJECT REPORT

Submitted by

Mr. SHAMBHU S. VASANI

200150109509

In partial fulfilment for the award of the degree of

BACHELOR OF ENGINEERING

in

Electrical Engineering

at

Government Engineering College- Bhuj

Gujarat Technological University, Ahmadabad

May, 2023

Gujarat Technological University 1 G.E.C BHUJ

 Project ID: 296217

GOVERNMENT ENGINEERING COLLEGE–BHUJ

CERTIFICATE

This is to certify that the internship report submitted along with the entitled
Internship has been carried out by Mr. SHAMBHU S. VASANI
(200150109509) under my guidance in partial fulfilment for the degree of
Bachelor of Engineering in Electrical Engineering, 8th Semester of Gujarat
Technological University, Ahmadabad during the academic year 2022-23.

PROF. N. H. ADROJA PROF. M. B. JHALA

Internal Guide Head of the Department

Gujarat Technological University 2 G.E.C BHUJ

 Project ID: 296217

COMPLETION CERTIFICATE

Gujarat Technological University 3 G.E.C BHUJ

 Project ID: 296217

COMPANY CERTIFICATE

Gujarat Technological University 4 G.E.C BHUJ

 Project ID: 296217

GOVERNMENT ENGINEERING COLLEGE–BHUJ

DECLARATION
We hereby declare that the internship report submitted along with the internship entitled
internship submitted in partial fulfilment for the degree of Bachelor of Engineering in
Electrical Engineering to Gujarat Technological University, Ahmadabad, is a Bonafide
record of original project work carried out by me at TOP CRANE PVT. LTD. /Government
Engineering College-Bhuj under the supervision of industrial guide Mr. Ramesh Pithiya
/internal guide N. H. Adroja and that no part of this report has been directly copied from
any students reports or taken from any other source, without providing due reference.

Name of the Student Sign of Student

__________________ _________________

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 Project ID: 296217

ACKNOWLEDGEMENT

I would like to acknowledge and express my deep gratitude to all the person who have been
my constant support and helped me in successfully completing this internship report for the
submission.

I am highly indebted to Assistant Prof. N. H. ADROJA & HOD M. B. JHALA for their
guidance and constant supervision as well as providing necessary information regarding
the internship and also for their support in completing the internship.

I would also like to express my special thanks to Mr. PIYUSH SOJITRA, Supervisor of the
site, giving me a chance to spend my practice in his company and helping me in my day-
to-day activities during the internship.

We are especially very much thankful to all engineer and technician, who took great effort
to share his practical knowledge to enhance the technical skill of the students.

I have Extend my supreme gratitude to Gujarat Technological University institute of

technology for Providing such kind of opportunity for students to broaden their perception
on how the real world in the field of electrical engineering looks like as well organizing the
whole internship program and its effort to make sure that the whole internship program to
achieve its desired goals.

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 Project ID: 296217

ABSTRACT

This Internship Report represents the function of TOP CRANE PVT. LTD. Located at
Piplana village in Rajkot district. The report discussed about basic function of Electric
crane wiring, Electric crane panel wiring, Radio remote connection, and Installation
process of crane. Here EOT Crane, Crab crane, and chain hoist are also discussed.

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LISTOFFIGURES
Fig1.1 Electric Cranes ................................................... Error! Bookmark not defined.

Fig1.2 Electric wire rope hoist ...................................... Error! Bookmark not defined.

Fig 3.1 Electric wire rope hoist ..................................... Error! Bookmark not defined.

Fig 3.1 wire rope HOIST .............................................. Error! Bookmark not defined.

Fig 3.2 Span .................................................................. Error! Bookmark not defined.

Fig 3.3 End carrage ....................................................... Error! Bookmark not defined.

Fig 3.4 bus bar and current collector ............................. Error! Bookmark not defined.

Fig 3.5Cable trolley ....................................................... Error! Bookmark not defined.

Fig 3.6Wired remote ..................................................... Error! Bookmark not defined.

Fig 3.7 Wireless remote ................................................ Error! Bookmark not defined.

Fig 3.8 Wireless double speed remote .......................... Error! Bookmark not defined.

Fig 3.9 Lifting hook ...................................................... Error! Bookmark not defined.

Fig 3.10Wire rope ......................................................... Error! Bookmark not defined.

Fig 3.11CT/LT motor .................................................... Error! Bookmark not defined.

Fig 3.12 Hoist motor with gear ..................................... Error! Bookmark not defined.

Fig 3.13 DC break ......................................................... Error! Bookmark not defined.

Fig 3.14 AC break ......................................................... Error! Bookmark not defined.

Fig 3.15 Thruster break ................................................. Error! Bookmark not defined.

Fig 3.16 Rotary gear type limit switch .......................... Error! Bookmark not defined.

Fig 3.17 Wheels ............................................................ Error! Bookmark not defined.

Fig 3.17 chain hoist ....................................................... Error! Bookmark not defined.

Fig 3.18 jib crane........................................................... Error! Bookmark not defined.

Fig 3.19 Electric crab .................................................... Error! Bookmark not defined.

Fig.4.1Diagram of four way panel ................................ Error! Bookmark not defined.

Fig.4.2 5 MT panel photo .............................................. Error! Bookmark not defined.

Fig4.3 Contactor ............................................................ Error! Bookmark not defined.

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Fig.4.4Wire ........................................................................ Error! Bookmark not defined.

Fig.4.5 PVC Cable tray ...................................................... Error! Bookmark not defined.

Fig 4.7 Metal strip .............................................................. Error! Bookmark not defined.

Fig.4.8 auxiliary contactorx ............................................... Error! Bookmark not defined.

Fig 4.Rectifier .................................................................... Error! Bookmark not defined.

Fig 4.9 Line choke ............................................................. Error! Bookmark not defined.

Fig.4.10 Transformer ......................................................... Error! Bookmark not defined.

Fig.4.11ATV 310 Schneider .............................................. Error! Bookmark not defined.

Fig.4.12. ATV 310 Schneider ............................................ Error! Bookmark not defined.

Fig.4.13 diagram of ATV 310 ............................................ Error! Bookmark not defined.

Fig.4.14 phase sequence with diagram .............................. Error! Bookmark not defined.

Fig.4.15 MCB .................................................................... Error! Bookmark not defined.

Fig. 4.16 braking resistors .................................................. Error! Bookmark not defined.

Fig. 4.17 END PLATE, END BLOCK, TERMINALS ..... Error! Bookmark not defined.

Fig.5.1 Auto gear box ........................................................ Error! Bookmark not defined.

Fig.5.2 Manual gear box .................................................... Error! Bookmark not defined.

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TABLE OF CANTENT

Acknowledgement ................................................................ Error! Bookmark not defined.

Abstract ................................................................................. Error! Bookmark not defined.

List Of Figures ...................................................................... Error! Bookmark not defined.

Learning Objective Of Internship ...................................... Error! Bookmark not defined.

Information Of Company .................................................... Error! Bookmark not defined.

Company Profile:- .............................................................. Error! Bookmark not defined.

Chapter 1- Introduction ...................................................... Error! Bookmark not defined.

1.1- Electric Crane ............................................................. Error! Bookmark not defined.

1.2- Used Of Electric Cranes ............................................. Error! Bookmark not defined.

Chapter 2- Safety Precaution .............................................. Error! Bookmark not defined.

Chapter 3- Types Of Cranes ............................................... Error! Bookmark not defined.

3.1 - Equipement Of Eot ........................................................... Error! Bookmark not defined.

3.2 – Chain Hoist ............................................................... Error! Bookmark not defined.

3.3 - Jib Crane .................................................................... Error! Bookmark not defined.

3.4 - Crab Crane ................................................................. Error! Bookmark not defined.

Chapter 4: Panel................................................................... Error! Bookmark not defined.

4.1: Various Type Panel Manufacture By Company ......... Error! Bookmark not defined.

4.2: List Of Components Used In A Panel Manufacturing Error! Bookmark not defined.

Chapter 5: Types Of Gear Box Used In Crane .............................................................45

Conclusion ........................................................................................................................50

Reference ..........................................................................................................................51

Gujarat Technological University 10 G.E.C BHUJ

 Project ID: 296217 Learning objective if internship

LEARNING OBJECTIVE OF INTERNSHIP

➢ This summary is a brief description of my internship I did in the company of ‘TOP CRANE
PVT. LTD.’ for a period of 3 month which was a learning and new experience as I got to
witness the practical application of engineering which studied in my books only.
➢ For an engineering student internship plays a very extensive role as It means that a student is
getting familiar to practical atmosphere and helps him to learn statics of a good engineer from
early age.
➢ I was also given the opportunity to sit during discussion with senior as well as the opportunity
to prepare equipment after conference with seniors.
➢ I have learned a lot with the help of this internship.

Gujarat Technological University 11 G.E.C BHUJ

 Project ID: 296217 Introduction

INFORMATIONOFCOMPANY
COMPANY PROFILE: -
➢ TOP CRANE PVT. LTD IS PRIVET COMPANY
➢ Company Annual turnover Rs. 10–12crore.
➢ ISO 9001:2020

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 Project ID: 296217 Introduction

CHAPTER 1- INTRODUCTION
1.1- ELECTRIC CRANE
➢ Electric cranes can be designed in many configurations, but they are usually called upon when
the power and scale of a large, gas powered or hydraulic crane is not necessary or is too
expensive. Jib cranes, bridge cranes, stacker cranes and many other crane configurations can
all be powered by electricity.

Fig1.1 Electric Cranes

1.2- USED OF ELECTRIC CRANES

➢ Electric overhead travelling cranes or EOT cranes are a common type of overhead crane,
also called bridge crane. They consist of parallel runways, much akin to rails of a railroad, with
a travelling bridge spanning the gap. EOT cranes are specifically powered by electricity.

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 Project ID: 296217 Introduction

Fig1.2 Electric wire rope hoist

➢ Cranes are indispensable for industries and working landscapes. They are most commonly used
in the automotive, construction, and shipbuilding industries. They are used to lift and handle
heavy objects and materials that are not possible manually. They make the work easier and
enhance productivity.

➢ It is mainly used for lifting heavy objects and transporting them to other places. The device
uses one or more simple machines to create mechanical advantage and thus move loads beyond
the normal capability of a human.

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 Project ID: 296217 Safety precaution

CHAPTER 2- SAFETY PRECAUTION

Sr. No. Description Examples

There are no new hazards on the operating

environment.

Fig 4.1

Assumptions and doubts lead to accidents.

Crane must take the load from the center not

from the side. Avoid swinging of the load

Don’t lift the load over people

Fig 4.4

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 Project ID: 296217 Safety precaution

Don’t pull the hoist rope or chain as a sling

Fig 4.5

Don’t try to be a multi-tasker

Fig 4.6

Ensure the load is connected properly and

communicate clearly with other team members

Fig 4.7

Ensure the clearance between cranes and fixed

objects.

Fig 4.8

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 Project ID: 296217 Safety precaution

Don’t leave suspended load unattended

Fig 4.9

➢ DO NOT USE DAMAGED AND UNSAFE TOOLS/EQUIPMENTS.

➢ DO NOT WORK IN HAZARDOUS AREA WITHOUT PERMIT.

➢ DO NOT OVERLOAD THE MACHINES THEN THEIR DESIGNED CAPACITY.

➢ WEAR SAFETY SHOES AND HELMET.

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 Project ID: 296217 Types of cranes

CHAPTER 3- TYPES OF CRANES

➢ WIRE ROPE HOIST OR EOT CRANE

➢ CHAIN HOIST
➢ JIB CRANE
➢ CRAB CRANE
➢ SINGLE GIRDER CRANE
➢ DOUBLE GIRDER CRANE

3.1- EQUIPEMENT OF EOT

➢ HOIST / CRAB
➢ SPAN
➢ LT GIRDER
➢ END CARRAGE
➢ BUS BAR AND CURRENT COLLECTOR
➢ C-RAIL
➢ CABLE TROLLEY
➢ PENDENT
➢ LIFTING HOOK
➢ WIRE ROPE
➢ CT MOTOR
➢ LT MOTOR
➢ HOIST MOTOR
➢ BRACKS
➢ LIMITE SWITCH
➢ WEELS
➢ PENAL

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 Project ID: 296217 Types of cranes

Fig 3.1 Electric wire rope hoist

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 Project ID: 296217 Types of cranes

3.1.1 - EQUIPEMENT OF EOT

➢ HOIST / CRAB

Fig 3.1 wire rope HOIST

➢ SPAN

The crane span is the measured canter to canter distance between the runway beams. One
of the most important measurements you can provide duringan overhead crane consultation is
the crane's span.

Fig 3.2 Span

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 Project ID: 296217 Types of cranes

LT GIRDER

➢ END CARRAGE

TWO TYPES OF END CARRAGE USED IN EOT

1. L TYPE END CARRAGE

2. BOX TYPE END CARRAGE

Fig 3.3 End carrage

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 Project ID: 296217 Types of cranes

➢ BUS BAR AND CURRENT COLLECTOR

• Crane busbar is used to supply power to travelling overhead crane. It consists of two parts, the
bus bar guide rail (fixed part, connected with the power supply and the collector. Crane bus bar
is used to supply power to travelling overhead crane.

Fig 3.4 bus bar and current collector

➢ C-RAIL AND CABLE TROLLEY

• C - Track Rail Festoon system is a festooning system for smooth management of high current
carrying cables used in EOT overhead cranes, hoists and any other industrial mobile
equipment. This type of festoon system comes in various types and sizes.

Fig 3.5Cable trolley

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➢ PENDENT

• Two types of remote used in cranes.

1. Wired remote
2. Wireless remote
Model: PL07K G.G.
Pendent used for control the cranes.

Fig 3.6Wired remote

• IN REMOTE CONNECTION 8 CORE WIRE USED AND IT’S OPERATE ON 110 VOLT.

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➢ WIRELESS REMOTE

Fig 3.7Wireless remote

Model: CMK F21-E1B

Volt: 415v

Transmitter volt: 9v D.C.

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 Project ID: 296217 Types of cranes

➢ DOUBLE SPEED WIRE LESS REMOTE

Fig 3.8 Wireless double speed remote

Model: CMK F21-B

Volt: 230v to 415v

Transmitter volt: 9v D.C.

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 Project ID: 296217 Types of cranes

➢ LIFTING HOOK

➢ A lifting hook is a device for grabbing and lifting loads by means of a device such as
a hoist or crane. A lifting hook is usually equipped with a safety latch to prevent the
disengagement of the lifting wire rope sling, chain or rope to which the load is attached.

➢ A hook may have one or more built-in pulley sheaves as a block and tackle to multiply the
lifting force.

Fig 3.9 Lifting hook

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 Project ID: 296217 Types of cranes

➢ WIRE ROPE

Galvanized Steel Wire Rope is Used for Crane Applications.

Fig 3.10Wire rope

➢ Wire ropes are used dynamically for lifting and hoisting in cranes and elevators, and for
transmission of mechanical power.

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➢ CT MOTOR / LT MOTOR

• Conventional AC operated electric overhead travelling (EOT) cranes uses slip ring
induction motors whose rotor windings are connected to a power resistance. Speed control is
performed by changing the rotor resistance in 3 to 4 steps by power contactors.

Fig 3.11CT/LT motor

➢ RATING

• MAKE: BHARAT BIJALI

• POWER: 2 HP (1.5 KW)
• AMP: 3.8 AMP
• VOL :415 V
• RPM: 1440

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➢ HOIST MOTOR WITH GEAR BOX

• Electric chain hoists use a load chain as the lifting medium. The load chain is pulled by a motor
that converts electrical energy to mechanical energy used to lift the load. The electric hoist
motor is housed inside a heat-dissipating shell, which is typically made from aluminium.

Fig 3.12 Hoist motor with gear

1. RATING

• MAKE: PBL
• POWER: 5 HP (4.4 KW)
• AMP: 7.8 AMP
• VOLT:415 V
• RPM :1440

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➢ BREAKS

• Hoist brakes are essential for crane safety. Hoist brakes are an essential safety feature of
overhead cranes. Designed to hold a load when the hoist motor is not running, these brakes
reduce the risk of falling loads that could result in injury and property damage.

➢ TYPES OF BREAK IS USED IN CRANE

• BREAK IS GENERALLY USED FOR STOP THE MOTOR ROTATION IN A CRANE.

• IN An ELECTRIC CRANE,

1. D.C. BREAK
2. A.C. BREAK
3. THRUSTER BREAK

1. D.C. BREAK

Fig 3.13DC break

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 Project ID: 296217 Types of cranes

2. A.C. BREAK

Fig 3.14 AC break

RATING

• VOLTAGE: 440V

3. THRUSTER BREAK

Fig 3.15 Thruster break

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➢ LIMIT SWITCH

• The main objective of a limit switch in EOT cranes and other industrial and marine machinery
is to prevent the damage and fatal accidents of any equipment nearby, and at the same time,
the limit switch can prevent injuries to the labourers who work in the area by reducing and
limiting the movement of the cranes that

There are three types of limit switch used in EOT,

1 Rotary gear limit switch

2 LSR limit switch

3 Lever type limit switch

Fig 3.16 Rotary gear type limit switch

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➢ WEELS

There are two types of wheels,

1. Flat wheels
2. Angle wheels

Fig 3.17 Wheels

3.2 – CHAIN HOIST

• A chain hoist is a mechanism that exerts a force for lifting or lowering an object by utilizing a
drum or lift wheel around which rope or chain wraps. Friction brakes help hold the load or
object and can be used to help control the descent of the load.

Fig 3.17 chain hoist

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 Project ID: 296217 Types of cranes

• CAPACITY: 1MT, 2MT, 3MT, 5MT

• DIRECTION: TWO WAY, FOUR WAY, SIX WAY

3.3 - JIB CRANE

• A jib crane is a lifting device with an arm or boom that extends off the main body of the crane
to provide extra reach and has a lattice design to lower weight added to a load. The design of
jib cranes allows them to work well in small work spaces completing repetitive lifting tasks.
They are extremely flexible and versatile cranes with a simple design capable of lifting 1 MT.
up to 5 MT.

Fig 3.18 jib crane

• CAPACITY: 1MT, 2MT, 3MT, 5MT

• DIRECTION: TWO WAY, FOUR WAY

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3.4 CRAB CRANE

➢ The Crab includes the hoisting machinery placed on a frame, which is in turn fixed on at least
four wheels and consists of suitable machinery for traversing the Crab to and for motion along
the main bridge girders of the crane. The crab wheels operate on two rail sections mounted on
the top flange of the main bridge.

Fig 3.19 Electric crab

• CAPACITY: 2MT, 5MT, 7.5MT, 10MT, 20MT

• DIRECTION: SIX WAY

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 Project ID: 296217 Panel

CHAPTER 4: PANEL

4.1:VARIOUS TYPE PANEL MANUFACTURE BY COMPANY

➢ TWO WAY PANEL

➢ FOUR WAY PANEL

➢ SIX WAY PANEL

➢ WITH HOIST DRIVE AND L.T. DRIVE PANEL

➢ ALL DIRECTIONS DRIVE WITH SELECTOR SWITCH TYPE PANEL.

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➢ FOUR WAY PANEL DIAGRAM

Fig.4.1Diagram of four-way panel

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➢ WITH HOIST DRIVE AND L.T. DRIVE PANEL

Fig.4.2 5 MT panel photo

4.2: LIST OF COMPONENTS USED IN A PANEL

MANUFACTURING
1. CONACTORS
2. WIRES
3. CABLE TRAY
4. METAL STRIP
5. RECTIFIER
6. AUXILARY CONTACTOR
7. LINE CHOCK
8. TRANSFORMER
9. VARIABLE FREQUENCY DRIVE
10. INSULATED LUG AND NON-INSULATED LUG

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11. R Y B INDICATORS
12. PHASE SEQUENCE
13. MCB
14. DBR
15. END PLATE, END BLOCK, TERMINALS

➢ CONTACTORS

• A contactor is a special type of relay used for switching an electrical circuit on or off. They are
most commonly used with electric motors and lighting applications.

Fig4.3 Contactor

• MAKE: Schneider
• Current capacity: 25A
• Model: Schneider LC1E25
• Current capacity: 25A
• Operating Volt: 110V

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➢ WIRES

• In a panel wiring o.75mm, 1.5mm, and 2.5mm wire used.

Fig.4.4Wire

➢ CABLE TRAY

• Cable trays are a mechanical support system that can support electrical cables used for power
distribution, control, and communication. They are the perfect solution for running large
quantities of power or data cables overhead or under-floor.

Fig.4.5 PVC Cable tray

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➢ METAL STRIP

• Metal strip used for mounting all components on penal and its hold the components.

Fig 4.7 Metal strip

• RECTIFIER

• A rectifier is an electronic device that converts an alternating current into a direct current by
using one or more P-N junction diodes.
• When DC Break is used in Hoist motor that time Rectifier is used in panel.

Fig 4.6Rectifier

RATING
• INPUT VOLTAGE: 190 TO440 VOLT
• CURRENT: 2 AMP

➢ ADDON BLOCK

➢ When extra NORMALLY OPEN connector is required in panel auxiliary is used, its mount
on a contactor.

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Fig.4.8auxiliary contactor

➢ LINE CHOCK

• Choke is a coil of wire around a magnetic core that creates a magnetic field when current flows
through it. This magnetic field increases the impedance of the line and reduces the total
harmonic content injected from the drive onto the facilities electrical system.

Fig 4.9 Line choke

2. RATING

• Voltage: 440
• Amp: 15A

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3. TRANSFORMER

Fig.4.10 Transformer

• POWER: 75VA
• INPUT VOLT: 440V
• OUTPUT VOLT: 110V

• Transformers provide voltage regulation and convert high or low voltages to match application
needs. In addition, they isolate systems from another.
• In EOT panel a transformer is use for provide 110v to contactor.

4. VARIABLE FREQUENCY DRIVE

• Variable frequency drives, or VFDs, are a type of AC motor controller that drive an electric
motor by varying the frequency and voltage supplied to it.

Fig.4.11ATV 310 Schneider

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 Project ID: 296217 Panel

• Model: ATV310U4N4C
• Power rating: 1.5Kw [ 2 HP]
• Voltage: 380v to 480v

➢ DRIVE PERAMITER

Fig.4.12. ATV 310 Schneider

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5. DIAGRAM OF ATV 310

Fig.4.13 diagram of ATV 310

6. PHASE SEQUENCE

• Phase-sequence relays DRR10 measure the sequence of the phases when being switched on
and switch - if necessary - the rotation of the field by changing 2 phases. The integrated PTC-
monitor protects the motor from overheating. more search for faults or change of wiring
necessary.

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Fig.4.14 phase sequence with diagram

7. MCB

• They provide protection against overload and short circuits in electrical circuits and equipment
in panel. They can also be used for non-frequent changeover of electrical circuits.

Fig.4.15 MCB

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8. DBR (Dynamic braking resistors)

• Dynamic braking resistors (DBRs) produce braking torque and absorb the high amounts of
energy generated by stopping electric motors. They are used in variable-speed drive systems
such as elevators, cranes, and trains

Fig.4.16 braking resistors

9. END PLATE, END BLOCK, TERMINALS

• Terminal blocks are connectors that terminate a single wire and connect it to a circuit or other
system.
• An end plate is a component that is placed at the end of a terminal block when a single terminal
block is connected to form a unit.
• End block is placed in last of the component on metal strip for hold it.

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Fig. 4.17End Plate, End Block, Terminals

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 Project ID: 296217 Types of gear box used in crane

CHAPTER 5: TYPES OF GEAR BOX USED IN CRANE

➢ Mainly in EOT Two type of gear box is used.

1. AUTO GEAR BOX

2. MANUAL GEAR BOX

1. AUTO GEAR BOX

Fig.5.1 Auto gear box

2. MANUAL GEAR BOX

Fig.5.2 Manual gear box

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 Project ID: 296217 Conclusion

CONCLUSION

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 Project ID: 296217 Reference

REFERANCE

1. https://www.topcranesystem.in/
2. http://indianmart.com/
3. https://www.giovenzana.com/
4. https://www.cmkelectropower.com/
5. https://www.google.com/search?q=indiamart&oq=indiamart&aqs=chrome..69i57j69i60l6.33
84j0j1&client=ms
6. https://m.indiamart.com/proddetail/crane-spare-parts-22511533291.html
7. https://www.dqcranes.com/knowledge/choose-single-pole-slide-wire.html
8. https://www.researchgate.net/figure/Various-parts-of-single-girder-3-ton-EOT-crane-
Courtesy-wwwoverheadcraneskitcom_fig2_349327116
9. https://www.hoistsandcrane.com/blog/various-kinds-of-eot-crane-manufacturers-in-india/

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