LARSEN & TOUBRO LIMITED BOP PACKAGE L&T Project No. : DBC104 L&T-S&L Job No.

: L609000

D B SUPER THERMAL POWER PROJECT-2 x 600 MW Village Baradarha, Janjgir-Champa, Chhattisgarh

BALANCE OF PLANT PACKAGE

L&T-S&L LIMITED Rev.: A

DESIGN BASIS REPORT - MECHANICAL

L&T-S&L Document No.: L609000-XW01-00-ZEN-020001

Date: 17/11/2010 Page: 152 of 369

CHAPTER : 13 13.1.0 INTRODUCTION

MISCELLANEOUS CRANES AND HOISTS

This chapter illustrates in brief the function, general description and design basis of Miscellaneous cranes and hoists for 2x600MW Balance of Plant of DB Power Project.

13.2.0 13.2.1

SYSTEM DESCRIPTION System Function The function of miscellaneous cranes and hoists are to ensure handling of various equipments during erection and maintenance.

13.3.0 13.3.1 13.3.1.1

DESIGN BASIS MISCELLANEOUS EOT CRANES Duty Class: Mechanism class M5 Electrical Service class M8

13.3.1.2

Capacity The safe working load (Y) for each of the miscellaneous cranes shall be computed as, Y = 1.10 x a Where, a = Single heaviest component to be handled. Capacity (safe working load) of various EOT cranes shall be considered as per attached Annexure-I.

13.3.1.3

Factor of safety In the design of components on the basis of strength, factor of safety shall not be less than five (5) based on ultimate strength. Impact, fatigue, wear and stress concentration factors shall be taken into account, wherever applicable. Factor of safety for wire rope shall be considered as per IS:3177.

LARSEN & TOUBRO LIMITED BOP PACKAGE L&T Project No. : DBC104 L&T-S&L Job No.: L609000

D B SUPER THERMAL POWER PROJECT-2 x 600 MW Village Baradarha, Janjgir-Champa, Chhattisgarh

BALANCE OF PLANT PACKAGE

L&T-S&L LIMITED Rev.: A

DESIGN BASIS REPORT - MECHANICAL

L&T-S&L Document No.: L609000-XW01-00-ZEN-020001

Date: 17/11/2010 Page: 153 of 369

13.3.1.4 13.3.1.5

Hook lift Highest Position Highest position of the hook shall be such that during operation of crane, the vertical distance between bottom of any equipment handled and top of any permanent structure or equipment in the operating area shall be approximately one meter.

13.3.1.6

Lowest Position The main hooks of the turbine hall cranes should reach upto the ground floor level. The auxiliary hook should reach upto the condenser pit level. In case of all other E.O.T cranes, the lifting hooks should reach upto the floor of its operating area/ground floor/sump pits as applicable.

13.3.1.7

Horizontal clearance Horizontal clearance like hook side approaches, end approaches etc. shall be worked out as per layout requirement.

13.3.1.8

Speed of EOT crane Main speed Main hoist Speed (TG Hall Auxiliary hoist EOT crane) CT LT Speed (Other miscellaneous crane) Main hoist Auxiliary hoist CT LT x x 1.5 m/ min 3.0 m/ min 10.0 m/ min 15.0 m/ min 1.5 m/ min Not applicable 15 m/min 25 m/min Creep speed 0.15 m/ min 0.3 m/ min 1.0 m/ min 1.5 m/ min 0.15 m/ min Not applicable 1.5 m/min 2.5 m/min

Above Creep speed shall be achieved through VVVF Drive. Tolerance of the speed shall be (+/-) 10% of rated speed.

LARSEN & TOUBRO LIMITED BOP PACKAGE L&T Project No. : DBC104 L&T-S&L Job No.: L609000

D B SUPER THERMAL POWER PROJECT-2 x 600 MW Village Baradarha, Janjgir-Champa, Chhattisgarh

BALANCE OF PLANT PACKAGE

L&T-S&L LIMITED Rev.: A

DESIGN BASIS REPORT - MECHANICAL

L&T-S&L Document No.: L609000-XW01-00-ZEN-020001

Date: 17/11/2010 Page: 154 of 369

13.3.1.9

Ruling dimensions and ratio a) For compression members, the slenderness ratio shall not exceed 120. In case of other load carrying members and subsidiary members the slenderness ratio shall not exceed 180. b) For girders, the following values of maximum span to depth ratio shall be governing: Plate girders: Span/depth = 18

13.3.1.10

Deflections and Camber a) The total maximum vertical deflection of the girders for the live load plus trolley and not including impact or dead load of the girder shall not exceed limit of Span/900. b) The girders shall be cambered by an amount equal to the maximum deflection due to dead load plus one half the live load and trolley.

13.3.1.11

Lifting Hook block assembly x Ramshorn type having capacity more than 40 tonnes (confirming to IS: 5749, IS: 3177) x Aux. hoist: Plain shank type having capacity less than 40 tonnes (confirming to IS: 15560, IS: 3177)

13.3.1.12

Material of construction Sl. No. 1. 2. 3. 4. 5. Components Bridge girder: Other structural members Lifting hooks Sheaves Wire rope Material of construction IS-2062 IS-2062 As per IS:1875 C.I. (IS-210, FG-260) IS:2266

LARSEN & TOUBRO LIMITED BOP PACKAGE L&T Project No. : DBC104 L&T-S&L Job No.: L609000

D B SUPER THERMAL POWER PROJECT-2 x 600 MW Village Baradarha, Janjgir-Champa, Chhattisgarh

BALANCE OF PLANT PACKAGE

L&T-S&L LIMITED Rev.: A

DESIGN BASIS REPORT - MECHANICAL

L&T-S&L Document No.: L609000-XW01-00-ZEN-020001

Date: 17/11/2010 Page: 155 of 369

13.3.1.13

Electrical Requirements x Motor will be Squirrel Cage Induction type designed for crane duty requirement of frequent starting, reversing and plugging. All motors shall be suitable for VVVF operation. x Motor ratings shall be calculated keeping margin of at least 15% over the maximum power requirement. Hoist motors shall be rated to lift the safe working load on the hook at the rated speed. x Power leads will run from the main disconnect switch to the runway conductors (DSL). The runway conductors will be four (4) in numbers for three phase supply and ground. The runway conductors shall be of MS Angle / Shrouded copper type. However, for small capacity cranes having lower spans, flexible copper cable will be used.

13.3.2

MISCELLANEOUS HOISTS Hoists shall be provided in those areas where any equipment/component weighing above 500 kg is installed and needs to be handled for maintenance purposes.

13.3.2.1

Duty/Mechanism Class x x Duty class - 2 as per IS-3832 (For Manual Hoists) Mechanism class - 2 as per IS-3938 (For Electrical Hoists)

13.3.2.2

Capacity x x Capacity of each hoist shall be 1.2 times the maximum working load. Hoist of capacity up to 3 tones shall be manual hoists. Hoists of capacity above 3 tones shall be electric hoists. x Manually operated hoists shall be of spur gear chain pulley block type and shall conform to IS: 3832.

LARSEN & TOUBRO LIMITED BOP PACKAGE L&T Project No. : DBC104 L&T-S&L Job No.: L609000

D B SUPER THERMAL POWER PROJECT-2 x 600 MW Village Baradarha, Janjgir-Champa, Chhattisgarh

BALANCE OF PLANT PACKAGE

L&T-S&L LIMITED Rev.: A

DESIGN BASIS REPORT - MECHANICAL

L&T-S&L Document No.: L609000-XW01-00-ZEN-020001

Date: 17/11/2010 Page: 156 of 369

Electric hoist shall be electric wire rope trolley suspended type and the design, operation, testing of electric hoist shall conform to IS: 3938.

13.3.2.3 13.3.2.4

Hook Lift Lift above operating floor Highest position of the hook shall be such that during operation of hoists, the vertical distance between bottom of any equipment handled and top of any permanent structure or equipment in the operating area shall be approximately one metre.

13.3.2.5

Approach below operating floor The lifting hooks should reach upto the floor of its operating area/ground floor/sump pits as applicable for the equipment weighing above half ton & needs to be handled for maintenance purposes.

13.3.2.6

Length of monorail hoist The horizontal distance between the centre line of the hoist and centre line of any installed equipment in its operating shall not be more than half meter.

13.3.2.7 13.3.2.8

Effort for Manual Hoists Hoisting x Hoisting effort for hoists shall not be more than 20 kg.

13.3.2.9

Trolley Motion x Effort for trolley motion shall not be more than 15 Kg.

13.3.2.10

Speed of electric Hoist x Minimum speed for hoisting shall be 3 m/min and that of for trolley motion shall be 15 m/min.

13.3.2.11

Material of construction x Load chain (where applicable) shall be of grade 40 as per IS:3109 and Hand chain shall be as per IS: 2429 (Part-I) grade 30.

LARSEN & TOUBRO LIMITED BOP PACKAGE L&T Project No. : DBC104 L&T-S&L Job No.: L609000

D B SUPER THERMAL POWER PROJECT-2 x 600 MW Village Baradarha, Janjgir-Champa, Chhattisgarh

BALANCE OF PLANT PACKAGE

L&T-S&L LIMITED Rev.: A

DESIGN BASIS REPORT - MECHANICAL

L&T-S&L Document No.: L609000-XW01-00-ZEN-020001

Date: 17/11/2010 Page: 157 of 369

13.4.0

CODES AND STANDARDS: Design, Manufacture, Inspection and testing of all the equipments of Miscellaneous cranes and hoists shall comply with all the currently available statutory regulations and safety code, as applicable.

13.5.0

REFERENCE Nil

13.6.0

ATTACHMENTS Annexure-13.6.1 : List of miscellaneous cranes and hoists

LARSEN & TOUBRO LIMITED BOP PACKAGE L&T Project No. : DBC104 L&T-S&L Job No.: L609000

D B SUPER THERMAL POWER PROJECT-2 x 600 MW Village Baradarha, Janjgir-Champa, Chhattisgarh

BALANCE OF PLANT PACKAGE

L&T-S&L LIMITED Rev.: A

DESIGN BASIS REPORT - MECHANICAL

L&T-S&L Document No.: L609000-XW01-00-ZEN-020001

Date: 17/11/2010 Page: 158 of 369

ANNEXURE-13.6.1 List of Miscellaneous Cranes & Hoists The Miscellaneous cranes and hoists shall be located at the following location. Sl. No. A 1. Location Miscellaneous EOT Cranes Turbine Hall Two (2) Nos. 115/25T - Indoor DG EOT Crane, for Independent operation 2. 3. 4. B 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. CW Pump House O & M Store House Compressor House Miscellaneous Hoists
LDO Pump House. Water Pre-treatment Plant DM Plant Effluent Treatment Plant Clarified Water Pump House Monorail Hoists covered in Ash Handling System Monorail Hoists covered in Coal Handling System Machine elevators. Clean Water Pump House Hydrogen Generation Plant room of all

Qty/Type

Control

Operators Cabin Pendant Pendant Pendant

One(1) No. 30T - Indoor EOT Crane One(1) No. 10T - Indoor EOT Crane One(1) No. 5T - Indoor EOT Crane

Electro-chlorination Plant Chemical House Centrifuge Building

Note: The monorail hoists represented above are indicative and the exact location, Type & Quantity would be finalized during detail engineering.