Welcome To My Presentation

Welcome To My Presentation1

Presenting By

Md. Fahad Hossain ID # 12107131 Program: BSME

IUBATInternational University of Business Agriculture & Technology

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Presentation On

A Study on Service & Maintenance of DEMAG Crane under Greenland Technologies Limited

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ContentsObjectives.Company Overview.Manufacturer Details.Different Types of DEMAG Crane.Different Part of DEMAG Crane. Details about Service & Maintenance.Recommendation.Conclusion.4

ObjectivesTo be Familiar with different types 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 know how to maintain Safety in work with DEMAG Crane and Components.

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Company OverviewGreenland Technologies Limited a concern of GETCO group provides sales & services of Four Different products, GETCO has various limited company Greenland Technologies Limited is one of them, which is most growing trading company in Bangladesh. This company dealing with four product such as Crane, Fork Lift, Cleaning Item- Sweeper Machine, Scrubber Machine, Vacuum Machine and New Holland Tractor. Manufacturer of New Holland Tractor is India and other three products manufacturer is German Origin. Greenland Technologies Limited is Supplying all this product in Bangladesh. They are doing both sales & Service.

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Cont.GETCO Group Greenland Technologies LimitedGreenland Engineers and Tractors CompanyGETCO Online Limited. GETCO Techno labs Limited.GETCO Digital Limited. GETCO Ventures International. GETCO Limited.GETCO Agri-Technologies Limited.

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Cont. Corporate Office:GETCO Group26 Shyamoli, Bir Uttam A. W.Chowdhury Road (Mirpur Road), Dhaka 1207, Bangladesh

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Company Key PersonsK. M. Khaled Chairman

Directors : Afroz BanueK. M. Rakib HasanK. M. Sakib HasanJ. P. AlamM. A. KhalequeGolam Arham Kibria

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VisionThe 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.

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MissionAs Greenland Technologies Limited is a concern of GETCO Group is 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 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.

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Manufacturer Details DEMAG Crane which is a 200 Years old Cranes Brand, still it is in number one brand in all over the world. 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 Dealer of DEMAG Cranes and in Bangladesh Greenland Technologies Limited is the Sub-Dealer of Terex Cranes & Components (I) Private Limited.12

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For 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. 14

Layout of DEMAG CraneDesigning DEMAG Crane based on India there is a team of more than 50 design engineers, these are the engineers are working in the design section efficiently to fulfill the market demand. 15

Different Types of DEMAG Crane16The different part of DEMAG Cranes are given below: Standard Crane Process CraneKBK CraneJIB CranePortal CraneSemi Portal Crane

Standard Crane DEMAG standard crane is the standard weight lifting solution for heavy industrial area. If we want to categorize standard crane, it can be two types one is single girder and another is double girder. Single girder crane is consist by only one girder, in which the hoist is adjust below the girder. Double girder crane consist by two girder and the hoist is adjust in the middle of two girder. Single girder crane is used to take the load up to 10 Ton and double girder is used to take the load up to 50 Ton. 17

Specifications of standard crane Single Girder Overhead Crane:SWL to 10 tSpan to 30 mLong travel speed to 40 m/minCross travel speed to 30 m/minHoist speed to 12.5 m/minDouble Girder Overhead CraneSWL to 50 tSpan to 30 mLong travel speed to 40 m/minCross travel speed to 25 m/minHoist speed to 12.5 m/min

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DEMAG 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. SWL: Minimum 50 Ton up to maximum 400 Ton. Span: Minimum 20 M up to Maximum 70 M. Lifting Speed: Minimum 1 M/m and Maximum 4 M/m.

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DEMAG KBK Crane

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. KBK Cranes minimum capacity is 125 kg to maximum it can take 3.2 Ton capacity.

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JIB CraneJIB 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.

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Portal Crane

Portal crane is manufactured by DEMAG Crane manufacturer for outdoor solution where there is no shade to setup overhead crane, on that time portal crane can be setup for example; Port and Shipyard. SWL is 3 Ton to up to 50 Ton and the span of the crane can be maximum 30 Miter. 22

Semi Portal and Portal Crane

Semi portal crane is manufactured by DEMAG Crane manufacturer for outdoor solution, 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 where one end of the crane will run on runway beam another end will run on floor, SWL is 3 Ton to up to 50 Ton and the span of the crane can be maximum 30 Miter.

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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.

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Different Part of DEMAG Crane

Main part of DEMAG Crane: GirderHoistEnd Carriage Power Supply LineTravel UnitControl SystemBottom BlockControl Panel

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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.

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Hoist27Hoist is most important part of crane, several parts are exist in hoist. There are two types of hoist one is chain hoist and another is rope hoist. Chain hoist can lift maximum weight 5 Ton and rope hoist can lift 400 Ton.

Different Parts of HoistGear BoxBrake Slipping clutch Rope Guide for rope hoistChain drive for chain hoistHoist motorSuspension BracketLimit Switch

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End Carriage End carriage is the part which is attached with the girder; In a crane two end carriage is attached with two end of the crane. there is a motor with each 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. There are two end stopper is attached with two end carriage.

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Power Supply Line

DENAG power supply line is made with well safety, the power supply line set with bay length of crane. The length of power supply is depend on the length of bay length. There are several dimensions of power supply line such as 4 meter, 2 meter and some times its also 1 meter length. 30

Travel Unit

DEMAG crane travel unit is consists by a motor, gear box and a wheel, the travel unit is attached with end carriage. the motor transmit the power and the crane run on runway rail by the wheel of travel unit.

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Control SystemDEMAG has three types of control system for their crane such as push button pendent with cable, radio control and Cabin Control System. Most of the time there are Push button pendent with cable is used, but in some cases there is use of radio control and cabin control system.

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Bottom Block

Bottom block is consists by hook, pulley and a handle. The crane take the load by attaching with hook. In the hook there is a lock which is used to keep the load inside the hook. 33

Control Panel Control Panel is set up very near to crane maintenance box, all the connection of hoist, pendent, end carriage motor connected with the control panel. 34

DEMAG crane 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 also training to their entire dealer service engineers. As Greenland technologies limited is local agent of DEMAG in Bangladesh, DEMAG has trained the service engineer of Greenland. Right now inside the Bangladesh service engineers of Greenland technologies limited providing service of existing DEMAG crane. 35

Existing DEMAG Crane in BangladeshAshuganj 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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Recent Service & Spare parts provided by Greenland Technologies LimitedSiemens Bangladesh Limited Summit Power Comilla PlantBangla Trac LimitedABB LimitedSummit Power Narayanganj PlantAbul Khair Steel Products Limited37

Service work of 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. 38

Cont.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

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Picture of Service Work in Siemens Bangladesh Limited

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Service Work of Bangla Trac LimitedIn 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 doesnt 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. 41

Cont.In their 10 Ton Crane there was a problem in runway rail and crane travelling wheel. When crane travel on runway rail it is 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 the pendent of this this crane there was a error code showing in pendent display, the error was 44 which the 5 number switch has no proper connection with contractor. After connecting properly the problem was fixed.

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Picture of problem checking in Bangla Trac Limited 43

Installation Process of DEMAG Crane Recently in Bangladesh there are four DEMAG Crane installed. All the cranes are different in capacity and dimensions. Those crane was 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 12.5 Ton Capacity crane. 44

Cont. 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. 45

Summary of Installation ProcessFor 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.46

Cont.After setting the End Carriage with the girder crane is stable 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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Cont. During my practicum period I was observed a complete DEMAG crane installation which was installed in Bargen Engine Bangladesh Limited. The details data of that crane is given below:Crane Capacity: 12.5 TonHook Path: 15 MSpan: 15.47 MBay Length: 50 MHoisting Speed: 1 to 4 M/minCross Travelling Speed: 5 to 15 M/minCrane Travelling Speed: 10 to 40 M/minTotal Crane Weight : 8 Ton

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Cont. In this picture it is showing that the crane is on floor, which is the initial condition of a crane before starting the installation process. In this girder two end carriage is set up properly at the two end of the crane and also the hoist is set up in the middle of the girder.49

Cont.In this picture it is showing the hoist which is set up in the middle of the girder. The hoist is consist by Rope Guide, Hoisting motor, cross travel motor, Bottom hook. Before lifting the crane on the run way beam the hoist was tested by operating with low speed on the floor. 50

Cont.After checking the hoist then all the flat cable set up with the crane girder. The flat cable is setup with festoon to run freely run with the hoist. In the festoon there are some clip attached by which the flat cable can run freely. 51

Cont.In this installation process most of the part of the crane was set up along with the crane before lifting the crane on the run way beam because there was available space in side the shade, but in some cases in side the shade does not get much more space to lift complete assemble crane, in such type of cases first end carriage set up on the run way rail and the girder lift on the run way beam and set with the end carriage. After assembling this two part then all other parts lift to set with crane. As in this case there was available space so after assembling all the parts crane was lifted by a mobile crane which lifting capacity was 50 ton. 52

Cont.53In this picture it is showing that how the crane girder is attaching with mobile crane, after attaching the girder properly with mobile crane, the lifting work start.

Cont.54In the time of crane lifting first of all, the crane girder was rotated according to how it will be set up, then the lifting was started.

Cont.In first time crane could not lift properly that is why one side of the crane girder was set properly on the runway beam but another side was not set properly. The scenario is shown in picture: 55

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Cont.In the second try crane was properly set up on the run way beam. After setting the crane on run way beam the next step is to set the control panel and to attached the maintenance box with the crane girder. 57

Cont. There are two maintenance box is attached with crane girder for future maintenance work of crane. The maintenance box, power supply line and control panel is set in the same side of crane, this is because of easy maintenance and check up.

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Cont.These are the power supply line, which is called DCL Bus bar, after setting all parts of crane then power supply line set up. There are several dimensions Bus bar such as 4 M, 3 M , 2 M and 1 m, but usually 4 and 2 M bus bar is used. 59

Cont.After set up power supply line, the electricity connection set up with power supply line and set the control pendent with the crane hoist, then the be ready to run. 60

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Maintenance We can define the maintenance as a set of organised activities that are carried out in order to keep an item in its best Operational condition. Activities of maintenance function could be either repair or replacement activities, which are necessary for an item to reach its acceptable productivity condition or operational activities, should be carried out with a minimum possible cost. As Crane is using to carrying heavy weight so it should be able to give full efficient operational output, to get full operational output crane maintenance should be properly done.

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Objectives of MaintenanceThere are so many things which we can get by proper maintenance, some objectives of maintenance are given below:To get efficient operation.Reducing break down and emergency shut down.Improving spare parts longevity.Optimising the useful life of equipment.Minimising energy usage

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DEMAG Maintenance ActivitiesDEMAG 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.65

Cont.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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Step of Greenland Technologies Limited for DEMAG Crane MaintenanceAs a sales and service provider of DEMAG crane in Bangladesh Greenland Technologies Limited try to established AMC- Annual Maintenance Contract with all clients of DEMAG crane in Bangladesh, already they are contacting with Abul Khair Steel Products Ltd. For AMC of their existing 16 DEMAG crane. Greenland Technologies Limited also has organized a preventive maintenance team those are visiting existing clients plant and checking the crane status and suggesting customer about their crane condition. 67

Recommendation

During the practicum period it was seemed to us that some necessary steps can be taken to develop the service and maintenance work, those are given below:Firstly I think safety should be main concern of us, but I have seen that Engineers and Technician was working without safety shoes and helmet which was very risky to work with heavy weight equipment. They need to use software based system for spare parts selecting, which will make the spare parts selecting and delivery very easier and faster. They should be more fast to provide emergency service. Clients should keep critical spare parts in their stock.It is important to ensure the companies transportation advantage for reaching at service side as early as possible. 68

ConclusionIt 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. 69

ANY QUESTION70

THANK YOU71