Benefits of Crane One-Time-Health-Checkup

by admin_bbt_cranedge

At present, every organization wants its operation to run uninterrupted with zero hurdles and with maximum efficiency. In maintaining the same, material handling equipment play an important role in achieving the objective. Regular overhead crane inspection and health check-ups give an overview of the current condition of the equipment. This also helps us to raise an alarm about any part which shows additional wear and tear. Cranedge health assessment reports help you to identify the pain areas of your crane and thereby making it possible to do proactive maintenance. This helps in keeping the crane in running condition by taking necessary action which further ensures trouble-free operation maximises the uptime and increases operational efficiency. Crane health check-up report from our team of experts helps you to take timely actions against upcoming issues.

Benefits of Crane Health Check-up:-

Maximum Uptime:

An overhead crane working without regular inspections is a potential candidate for a sudden downtime. However, regular inspections enable you to identify and address the issues before they become a major threat. This allows for maximum uptime of your equipment and helps to run your business with higher productivity.

Trouble-Free Operations:

Shop floor accidents and injuries pose a significant challenge to productivity and equipment uptime. However, regular inspections help the management to evade these threats and ensure maximum uptime. From human resources perspective, this will be a step towards their safety and get them more engaged with the organization with enhanced productivity.

Smooth Plant Working:

When you regularly inspect your material handling equipment, good maintenance and efficient operations of the plant becomes a habit. Proper maintenance keeps the MHE in good and smooth operating conditions. Such regular activity enables you to tackle the wear and tear of your equipment and keep productivity and efficiency in check.

Maximum Plant Efficiency:

In a process-based system, overhead cranes act as one of the critical components that contribute towards organizational efficiency and productivity. Thus, regular maintenance of such equipment becomes inevitable. Proper inspections at regular intervals ensure perfect working conditions for the overhead cranes. Such inspections not only ensure the safety of the shop floor but also produce multi-fold benefits such as an increase in revenue and profits.

Machinery Performance Life:

The useful life of an overhead crane is going to diminish significantly with regular use and wear and tear. And the only way to counter this threat is by conducting regular health check-ups. Such inspections help you to evade unforeseen dangers and get the most out of your investment.

An effective and regular inspection is essential in ensuring optimum working conditions of the overhead crane as well as to avoid any looming hazard at the facility.

Crane Wire Rope Hoist Maintenance Tips

by admin_bbt_cranedge

A wire rope hoist is nothing but a flexible rope comprising of several individual steel wires. They are all clubbed together and twisted to the center to form strands. These strands twisted together around the core forms a rope. Not every wire rope hoist has the same specification but has the same application.

A wire rope hoist is a component that undergoes severe wear and tear over a period of time. The more they are used, the more their condition deteriorates and the less efficient they become. However, regular wire rope inspection can help detect the deterioration and post maintenance corrections can increase their useful life and productivity.

Essential Wire Rope Hoists Inspection Tips:

Wire rope hoists play a critical role in crane functioning and operations. Regular inspection and maintenance of wire rope pays huge dividends in improving safety and productivity of the equipment and shop floor. But before we get into the maintenance tips, let’s explore the ways one can perform the inspection of the wire rope. A proper inspection requires the right tools and criteria for evaluating the condition of the wire rope.

  • To begin with clean the wire rope for any dust and rust such that any cracks, cuts, and tear is clearly visible.
  • Take a soft cloth or any fabric and move it over the wire rope as if to clean the surface. If the cloth gets stuck in between any broken area you will be able to find the damaged part.
  • Measure the diameter of the wire rope and compare it with original, standard wire rope, if you find a difference, it concludes that the wire has undergone some internal or external damage.
  • You can also check the interiors of wire rope for corrosion and abrasions by using a spike and moving it between the two strands of wire and opening them up.

Essential Wire Rope Hoists Maintenance Tips:

  • Conduct frequent and regular inspections of the wire rope essentially at the start of every shift or operation.
  • Sometimes the rope gets damaged inside the hoist drum and sheaves. Inspecting them on regular intervals prevents you from using a damaged wire rope and avoids a costly mishap.
  • Inspect the entire length of the wire rope until the point where the load is attached.
  • If you notice any broken wires, remove the wire rope hoist immediately.
  • The diameter of the wire rope gets diminished over a period of time with regular use. Depending upon the application, the reduction may happen sooner.
  • Other critical factors to look for are corrosion, rope deformation, and loose loops.
  • Always check for the cause of wear and tear post discarding of the damaged wire rope.

Safety Starts with our Crane AntiFall System

by admin_bbt_cranedge

What are Falling Materials and Why are they a Cause of Worry? – A Case Study

Falling materials are a major concern at any workplace or plant site wherever overhead cranes are installed. Load slippage, mechanical failure, or operator incompetency can all result in serious injuries or fatalities. If loads are not properly secured, the load can slip and land on workers in the vicinity or cause major damage to property. Loads being lifted by overhead hoists tend to be fairly heavy and cause serious damage when they eventually crash to the floor.

One of our prestigious customers and a major Indian auto giant faced one such unfortunate incident wherein the load from a 25t DGEOT crane, slipped and fell from a height of 8 meters. Although there were no casualties, there was some serious damage done to the machinery and there was the loss of property. This incident shook many within the company and posed a real threat to safety at the workplace. The customer is one of the most reputed companies that gives the utmost importance to the safety of its employees, immediately decided to consult one of the best in the business. Cranedge India Pvt. Ltd. with a decade of experience in EOT crane services, was invited for a detailed discussion to understand the reason for the mishap and to come up with an optimal solution to avoid any future accidents.

Crane Specialists at Work!

Cranedge sent a team of crane specialists, who went about their job with an eye for detail. They thoroughly checked the crane, analyzed the site & the application and even interacted with the crane operator and the workers to detect the reason for the failure. Backed by a strong design team, Cranedge came up with a bespoke solution with minimal changes in the existing system. The customer was so impressed with the technical expertise and the approach of the Cranedge team that they decided to place the order for executing the solution on not just one but 10 of their critical cranes at the same time.

Since the cranes were more than a decade old, Cranedge team conducted a thorough check on the cranes to understand the condition of the crane. The crane data were further analyzed with the Design team in consultation with the sales and service team to understand the requirement of the customer and to device a system that was both cost-effective as well as ensured a safe working environment with minimal changes in the existing system.

Our Solution

Crane Anti-Fall system was designed as a safety measure to alert the operator and the workers during the time of emergency. In cases where the hoisting brake fails, an alarm would go off notifying the operator and the workforce about the emergency. At this stage, the system is capable of holding the load for a period of around 10 minutes even after the hoisting brake completely fails thereby allowing the operator sufficient time to park the load at a safe location without having to worry about the load falling down. Once the situation is taken care off, the crane can be maintained and made ready for use once again.

The MH slip ring motors were replaced with VFD suitable squirrel cage motors, New VFD control panels with other accessories were provided, cable trailing systems were replaced with more robust drag chain systems. This system was implemented one by one, on each crane and was made ready for operation in a week’s time.

Though the Anti-fall system proved to be a real boon to enhance the safety of the crane, performing regular maintenance can be one of the easiest ways to reduce the risk of falling materials. Maintenance should always be of paramount importance when it comes to heavy machinery. If a moving part on an overhead crane wears out or breaks the hoist, it can cause serious damage. Performing regular maintenance ensures trouble-free and smooth operation of the hoists and overhead cranes. Cranedge India Pvt. Ltd offers a wide range of crane services that are customized according to the requirement and application of the crane. To avoid human error, Cranedge has also strategically developed advanced equipment’s like RAMON (Rail Monitoring System) for precise inspection & correction of crane geometry & rail alignment and ROMON (Rope Monitoring System) for timely prediction of rope failure.

Because Your Equipment Deserves the Best

by admin_bbt_cranedge

EOT (Electrical Overhead Travelling) Cranes forms an integral part of any industry for lifting and moving materials. Like any other equipment, the cranes undergo wear and tear over a period of time because of the laborious tasks they perform. It therefore becomes essential to have a scheduled maintenance program for the optimum utilization of the crane and trouble-free operation without compromising on the safety of the workforce.

What are the major reasons for the disruption of cranes?

1. Regular breakdowns
2. Outdated design
3. Vigorous duty cycles
4. Major mishaps that can occur due to improper handling.
5. Natural calamities.

Thus, cranes need to be regularly serviced & maintained because the breakdown can result in fatality for the work force, company, and eventually the brand.

We, as a professional crane service company are not only dedicated to providing complete after-sales services for a range of material handling equipment, but we also ensure an unmatched service throughout the life cycle of your equipment. Here are a few of them –

RAMON – Rail Monitoring

Track alignment, straightness, and parallelism are extremely important for the smooth and safe operation of your cranes. RAMON is a specialised and advanced crane rail monitoring system, strategically developed by Cranedge. Periodic rail monitoring helps in avoiding situations like –

• Premature wear & tear of wheels and rails.
• Failure of shaft and long travel motors
• Abnormal sound and vibrations.
• Unpredicted crane downtime
• Cost driven repairs or replacements.

ROMON – Rope Condition Monitoring

For long service performance of your crane, selection of the appropriate wire rope and maintaining its health is very important. Crane Wire rope can weaken with overuse and mishandling resulting in breakage or uneven lifting during operation. At Cranedge, we have developed a unique way to check the wire rope. A portable, non- destructive inspection equipment (ROMON) inspects the wire rope for –

  1. Strength
  2. Flexibility
  3. Resistance to abrasion
  4. crushing, fatigue, rotation, and corrosion.

Annual Maintenance Contracts (AMC)

Apart from the regular health checks of your cranes, a structured preventive maintenance plan is also important.
Annual Maintenance Contract helps in upkeeping the condition of the crane. It gives a regular update and helps you to take preventive measures to stay healthy. A similar thing happens with cranes. The health of a crane also depends on its periodical maintenance plan. A well-structured and detailed maintenance plan will ensure proper preventive measures, thereby warranting better longevity.

What is the Cranedge Advantage?

We have developed our Annual Maintenance Contract based on our experience, working with over 6500 cranes to a wide spectrum of industries in close to 60 countries across the world. Our AMCs cover all the crane components which ensures their performance ability at all levels of use

Remote Monitoring of Cranes

At Cranedge, we believe in the power of data. Our team has compiled the data of more than 35000 cranes of different makes and that acts as a knowledge bank for us. All our team members have an access to required data as they are all connected to the CMMS server and thus, they can serve you efficiently in a limited time period.

From retrofitting VFD drives to radio remote controls, Cranedge can offer best in class solutions to monitor your cranes without a need of being actually present at the sight. This offers a lot of convenience. With the ElectroMech expertise, we have devised solutions to monitor the cranes remotely using IoT, advanced electronics and WiFi communications. For instance, in EKK Infra project in Kerala, we had developed a solution where entire system was programmed for automatic sequential check-up which ensured enhanced safety.

EMote

EMote is an IOT supported solution that helps in remote diagnostics of crane health. Through this, Cranedge team is empowered to offer you remote support for crane operations – 24*7, at any given location.

All this and more, comes with the Cranedge promise of offering resolution for cranes under warranty, anywhere in the world – Within 48 hours. In our upcoming posts, we would continue to talk more about the crane service offerings and the benefits you would reap by your association with Cranedge.

Annual Maintenance Contracts for Crane

by admin_bbt_cranedge

cranes count among the most critical equipments for capital intensive industries like Infrastructure, Manufacturing, Steel, Power etc. It is therefore important to have a smooth and trouble-free operation of these cranes to ensure higher availability and uptime resulting in increased productivity and profitability.

A few compelling questions that bother all the above industries are:

  1. How to prolong the useful life of a crane?
  2. How to ensure optimum utilisation of the crane?
  3. How to predict breakdowns and enhance safety at the workplace?
  4. How to minimise the total cost of ownership?

The solution to all the above questions lies in ‘Annual Maintenance Contracts (AMC)’.

Now what exactly is Crane AMC and why are they essential?

In addition to regular health checks, your cranes require a structured preventive maintenance plan. This plan ensures that cranes provide long and reliable service while remaining in healthy condition. Under AMC, all the major parts and components of the crane are checked to ensure their integrity and ability to perform at all levels. AMC helps in the timely prediction of the health of the parts and components to avoid any undue circumstances leading to crane downtime and eventual production loss.

amc for cranes

How does a Crane AMC help?

  1. Regular maintenance of cranes under AMC helps to prolong the useful life of cranes and you can be assured that the cranes will continue to work with peak efficiency for years without frequent unexpected failure.
  2. Most AMCs provide emergency services, thus in the event of an unexpected failure of the cranes, a crane specialist will always be around you, well equipped with essential spare parts thereby saving time and money which results in productivity for your business.
  3. AMC helps you to reduce the cost of ownership.
  4. A crane specialist handling your equipment is essential for ensuring higher availability, higher uptime, lower MTTR and lower MTBF.

Why Cranedge?

  1. Cranedge Annual Maintenance Contracts have been developed based on our experience with over 10000 crane installations across the globe in almost every conceivable industry.
  2. Our wide range of Crane AMCs is customized according to the requirements and application of the equipment.
  3. Covering your cranes under a Cranedge AMC gives you timely inputs on the health of worn-out parts so that you are well prepared with timely replacement and prevent production downtime.
  4. Cranedge AMC covers all types of cranes from an EOT Crane (an overhead crane), a Gantry crane, a Jib crane, forklift to a simple light duty workshop crane. We have a specialised team who possess in-depth knowledge of cranes to help you find the right solutions.
  5. Cranedge also helps you to develop key performance indicators for your crane based on their operations and performance.
  6. Cranedge has a huge inventory of spares for all types of cranes thus making repair work convenient and time-saving.

As Albert Einstein once said, “A clever man solves a problem, a wise person avoids it.” An AMC for cranes does exactly the same, avoids the problems for your business!