Petroleum Development of Oman LLC

Specification for Electric Overhead Traveling Cranes

SP-2202

Petroleum Development Oman L.L.C

Specification for Electric Overhead Travelling Cranes

Document ID SP-2202

Document Type Specification

Security unrestricted

Discipline UEOD

Owner UEQ/3

Issue Date April 2016

Revision 0

Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part
of this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in any form
by any means (electronic, mechanical, reprographic recording or otherwise) without prior written consent of the
owner.

Document Authorization
 Revision History

Version No. Date Author Review By Approved By

Version 1 24 Mar 2016 Hugo MB den Boogert

1. GENERAL

1.1 Introduction

1.2 Reference documents

1.3 Codes and standards applicable to the design of overhead cranes and hoists

1.4 Abbreviations / Definitions

1.5 Documents precedence

1.6 Supplier standards

 1.7 Dimensions

2. SCOPE OF WORK
1. Scope of Supply
2. Spare parts
3. Exclusions

3. DESIGN REQUIREMENTS
1. General
2. Mechanical requirements
3. Structural requirements
4. Maintenance and access requirements
5. Electrical equipment

4. ENVIRONMENT AND SAFETY

1. Climatic data
2. Hazardous area classification
3. Human factor engineering (HFE)
4. Acoustic requirements
5. Safety requirements

5. INSPECTION AND TESTING

1. General
2. Classification / Certification
3. Inspection / shop testing
4. Field test
5. Material Certification

6. GUARANTEE AND WARRANTY

1. Mechanical Guarantees
2. Performance Guarantees

7. Name plates
8. Painting & Surface preparation

1. GENERAL
1. Introduction

This specification covers the minimum requirements for the design, documentation,
manufacture, spare parts, inspection and testing of the Overhead Traveling Cranes and
Hoists to be supplied on projects.

This document, in combination with the applicable industry standards, project standards,
technical specifications and specific data-sheets referenced herein and in the Material
Requisition, outlines the requirements for the supply of the Overhead Travelling Cranes
and Hoists.
 Where this Specification is applicable to a Sub-Supplier’s scope of supply, it shall be in
its entirety; sections of this Specification must not be extracted and used on a “stand
alone” basis.

1.2 Reference documents

Design requirements included in this document (paragraph 1.3) are in addition and
prevail to the relevant paragraphs of the specification.

Other project specifications and DEPs which are not specifically mentioned in this
document but listed in the Material Requisition are also applicable, as well as the Codes
and Standards to which they refer. Especially, with an intention of consistency within
Project’s overall engineering development, the Supplier must strictly comply with
numbering procedures for documents, tagging procedures for itemized mechanical and
electrical sub-items, instruments and piping, PFS and PEFS symbols.

Except otherwise noted, the latest edition of Codes and Standards shall be used. Future
Standards and Codes, Rules and Regulations published but not in force on the contract
date shall also be applied, subject to the approval by PDO.

1.3 Codes and standards applicable to the design of Overhead Cranes and Hoists

The following codes and standards, together with any documents referred to therein, shall
apply:

BS EN 15011:2011+A1: Cranes - Bridge and gantry cranes

EN 1991-3: Actions on structures

EN 14492-2: Power driven hoists

EN 13001-1: Crane -General design-General principles and requirements

BS EN 1993-1-1-2005 Design of Steel Structures

DD CEN/TS 13001-3-5:2010 Cranes- General design- Limit states and proof of

competence of forged hooks

BS EN 12385-1&4: Steel wire ropes

ISO 16625: Cranes and hoists- Selection of wire ropes, drums and sheaves.

ISO 4301-5 : Cranes - Classification - Part 5: Overhead Travelling and Portal Bridge
Cranes

DEP 31.25.00.10- Hosting Facilities and Weather protection for Rotating Equipment
 BS PD 5304: Guide line for safe use of machinery

PR-1710 : Lifting Equipment Numbering Procedure

SP- 2114 Maintenance Strategy of Overhead Travelling Cranes and associated

equipment

CONTRACTOR may consider SUPPLIER alternative Codes, Standards and

specifications (for instance BS-EN), provided that such alternatives are documented with
track records of proven performance in other projects.

However HSSE, Operability, Maintainability & Reliability performances shall not be

affected in the event of implementing such alternatives in the supply.

In the absence of an alternative proposal, it shall be understood that all requirements in

this specification and related documents are fulfilled without any exception.

1.4 Abbreviations / Definitions

Company Petroleum Development Oman LLC (PDO)

Contractor The party appointed by PDO and who is responsible for

the Engineering and Procurement of material / equipment.

DEP Design and Engineering Practice; standard for

subject or item, which is provided by Company in order to be
included in material Requisitions.

HFE Human Factor Engineering

MR Material Requisition

The document in which are listed all the project procedures,

specifications, data-sheets, standards, P&ID and drawings
applicable to the Package and its associated items.

NDE Non-Destructive Examination

Package All the equipment provided by the supplier

SP-Particular Technical Specification

This document aims to define a supply of equipment. SP is

attached to the relevant Material Requisition.
 Sub - Supplier The party which carries out all or part of
the design, procurement, installation and testing of the system(s) as
specified by the Supplier (or Prime Supplier).

Supplier The party which is responsible for the process

design, detail design, engineering, procurement, fabrication, testing
and preparation for shipment of the package. Refer also to
paragraph 1.5.

1.5 Document precedence

Project Specification is prepared out of the following references:

a. Statutory Regulations of Sultanate of Oman

b. International Codes and Standards
c. Company DEP and associated agreed COMPANY
amendments

When CONTRACTOR has prepared the Project Specification and

in case of inconsistencies or conflicts between the several
references, unless otherwise approved with COMPANY, the more
stringent shall apply.

Nevertheless, in case SUPPLIER identifies inconsistencies or

conflicts, which are not included in the present specification,
SUPPLIER shall seek clarification and obtain CONTRACTOR
consent and approval before implementation. CONTRACTOR
shall thus seek agreement with COMPANY on any deviations.

1.6 Supplier Standards

Subject to CONTRACTOR / COMPANY approval, SUPPLIER

standards may be proposed for the design of items not covered by
this specification.

1.7 Dimensions

The dimensions shall be specified in accordance with the list

provided in Annexure 1 & 2

2 SCOPE OF WORK
2.1 Scope of Supply

The Supplier must inform Contractor about all elements in the scope of
supply that might be inadequately defined or missing.

In addition to the specific requirements of the Material Requisition and

Individual Data-Sheets for girders, traversing trolleys and hoists, the
Supplier shall provide for each item the following (but not limited)
accessories, components and piece of equipment;

 Sheet metal or mesh grid metal casing to protect accessible

mechanical parts and impact proof casings for overhanging
elements.
 Resilient bumpers and rubber buffer or hydraulic bumpers where
necessary
 End stops at crane rail ends and/or at hoist beam ends.
 Name plates, visible and permanent (with maximum load
indicated)
 Anti-derailment devices
 Lubricators
 Chain guides and cable guides
 Hook with safety latch
 Rail sweep for permanent hoists and crane (hoists which are stored
in ware house when not used can be supplied without rail sweep)
 Oil and grease for the first filling
 Rails for crane including clamps and bolts
 Maintenance platform (if required in the Data-Sheet)
 Fittings and bolts
 Protective hood against sun for equipment located outdoor
 Special tools if necessary
 Surface finishing and painting
 For cranes including bridge walkways in their scope, handrails and
a life line shall be supplied all along in accordance with European
directive 89/686 (Personal Protective Equipment) and EN 795
Class C, including clamps and anchors.
 Chain baskets for chain hoists

When electrically motorized equipment is specified in the data sheet, the

following (but not limited) items shall be provided by the Supplier (see
also below);

 Main incomer isolation switch

 Isolator for the control power supply.
 Inhibition of starting in high speed
 Inhibition of braking in reverse at high speed
 Alarms (visual and/or acoustic) as required in the data-sheet
  Motors
 Motors’ sunshade (when hoisting equipment is not under a shelter)
 Motors’ earthing
 All necessary cables, conductors, collectors, festoons, tracks,
supports, hangers fittings etc. required to extend over the full
length of travel
 Safety chains on festoon
 Disconnecting switch with lock for the main switch box
 All cable glands
 Push button control box with on/off position secured by key.
 Protection relays including thermal, earth faults etc.
 Anti-condensation heater
 Motor starters including reversing, dual speed reversing, etc.
 Control voltage with transformers (control voltage derived from
the main power supply)
 Limit switches on all electrical moving parts with protections (one
for slow speed and one for stopping activation)
 Load limit switch with protection (unless otherwise specified in the
data-sheets)

Sketch of Hoist monorail

CONTRACTOR; beam with anchors

SUPPLIER; control cable with glands supports, fittings and clamps.

SUPPLIER; end stops with fittings and, if required, limit switches

SUPPLIER; remote control or pendant control, as specified by data-sheet

SUPPLIER; junction box with cable glands, power transformer, control

voltage

SUPPLIER; power cable with cable glands supports, fittings, clamps

SUPPLIER; power cable

SUPPLIER; junction switch box with cable glands, main disconnect

switch

CONTRACTOR; power cable

2.2 Spare Parts

 Supplier shall advise the recommended list of spare parts for erection, pre-
commissioning, commissioning and 2-years operation, including as a
minimum;

Gasket + o’ring+ seal: 1 set per type

Fuse elements: 1 set per type

Relays: 1 set per type

Limit switches: 1 set

Rail clamps and bolts: 2 sets per type

Visual alarms (lamp): 1 set per type

Discs for motor brakes: 1 set per type

Festoons trolleys and fittings; 1 set

Contactors: 1 set for each type of electromagnetic switch / starter

2.3 Exclusions

The following are excluded from Supplier scope:

 Erection at work site

 Connection and wiring of electrical power between site networks
and main disconnect switch
 Connection of the hoist earth circuit to the PDO earth network
 Beams for monorail hoists

3 DESIGN REQUIREMENTS

3.1 General

The equipment, including auxiliaries, covered by this specification shall be

designed and constructed for a service life of twenty-five (25) years.

The maximum permissible Safe Working Load of the Crane shall be clearly and
visibly marked on the equipment. The markings may be on a separate plate or
painted directly onto the crane structure. The letters and numbers shall be on at
least two opposing visible faces of the crane, and shall be in English.
 Hand operated travelling cranes shall be limited to the handling of loads not
exceeding 4 tonnes, with moderate lift frequency and when frequent and fast
crane operation is not foreseen.

The hoist brake system shall automatically prevent the load from falling in the
event of loss of electrical power and brake shall not overrun or creep. A system
for controlled lowering of the load under the conditions shall be proposed by the
Supplier. Brake shall be enclosed disc type no external brake is allowed.

Hoist slow speed between 0.3 m/min and 0.4m/min with Jog facility

Hoist fast speed between 4.5m/min and 5.5m/min with Jog facility

Cross travel speed between 8m/min and 10m/min with Jog facility

Long travel speed between 15m/min and 18m/min with Jog facility

3.2 Mechanical requirements.

 Energy absorbing end stop brackets and buffers shall be provided by

Suppliers at the limits of long travel and traverse motions. They shall be
designed to ensure that a fully loaded crane travelling at maximum speed
into the end stop will not cause any damage or promote a hazardous
situation.
 The supplier shall specify maximum resulting horizontal dynamic forces
of the trolley with maximum vertical load hitting the bumpers. As this
could impact building or structure design, this value shall be agreed
between Supplier and Contractor prior to any purchase order.
 Travel wheels shall be manufactured of non-sparking material such as
bronze alloy, brass, cast iron, etc. for hazardous areas.
 The crab of the crane shall be provided with an overload protection
device.
 The overload protection device shall be set to operate at 10% above the
crane safe working load.
 The overload device shall be designed to be tamper-proof.
 All rotating parts such as wheels, gears, motor, etc., shall be provided with
mechanism/ball or roller bearings totally isolated from the environment
(dust/sand proof). Bearings shall be in accordance with ISO standards.
Bearing service life (L 10H) shall be 20 000 hour.
 Mechanical moving parts (as travel wheels, gears, reeving) of the crane
shall be guarded. The guards shall be fabricated in non-sparking material
when cranes operate in hazardous areas. Plastic guards are not allowed.
  Unless otherwise specified in the data-sheet, chains are not accepted above
7 tones capacity or 30 meters length. Steel wire ropes shall be preferred to
chains.
 Sheaves shall be designed to prevent the wire rope from slipping off, and
to facilitate reeving.
 Sheaves shall have amachined rope surface and shall run on fully sealed
anti-friction bearings. The surface shall have hardness qualities compatible
with the rope recommended by the rope manufacturer
 Load hook shall incorporate safety latch and shall be swiveling type.
 The Crane hoisting wire ropes shall be designed to have a safety factor of
not less than 5 based on the maximum SWL of the crane.
 Ropes / chain shall be of a length to ensure no less than 5 full wraps on the
drum when the hook is at the lowest available position. Hook lowest
available positions shall be considered as 1 meter below the hook lowest
position specified on the data-sheet.
 Capacity of the winding drum shall be sized according to above rope /
chain length size requirement.
 Winding on drums shall be restricted to a single layer unless specifically
approved by the CONTRACTOR. When approved a maximum of two (2)
layers shall be wound on the drum.

3.3 Structural requirements

 Single girders maximum span shall not be more than 15mtrs and
maximum lift of height 10mtrs.
 Crane girders shall be designed for a maximum vertical deflection (under
test load) of L/750 of the span between the two rails.
 The fabrication of the crane structure / girder shall be such that no welding
shall be required on the site.
 Bolts used for bridge to end carriage connections should be of a minimum
grade 8.8,

3.4 Maintenance and access requirements

 The crane shall be designed with facilities for safe and easy access for
inspection and maintenance. These shall include walkways, platforms,
lighting and ladders as necessary.
 Minimum two lights(EX ‘e ‘/Ex ‘d’ type) shall be provided.(min. 50 Lux)
  Walkway with handrail shall be provided by Supplier along the entire
length of one side of the bridge girder crane. All clearances of walkway
heights shall be as specified by the Contractor.
 Minimum width of the Platforms shall be 750mm. For single girder cranes
2 platforms shall be provided at the end of the LT on opposite sides.
 For double girder cranes over the full length of CT, a platform is to be
provided.
 Minimum walkways width shall be 750mm.
 The minimum space between the crane maintenance platforms grating and
the lowest obstacle shall be 2m. In case this rule cannot be followed,
Supplier shall provide a protection cage preventing operators to be hurt.
 The minimum clearance between the runway axis and the edge of the wall
shall be at least 0.5m for the operator to be able to access the runway
whilst crane is operated.
 Minimum width of ladders shall be 0.3m and pitch shall not exceed 0.3m.
 Where the cranes are installed outdoors, locking devices shall be provided
for safe docking of the crane in any position.

3.5 Electrical equipment

The below paragraphs apply to electrical motorized cranes and hoists.

3.5.1 General

 Cranes shall have electric drives for hoisting, long and cross travel
motions. Unless otherwise stated in the Crane Data Sheets, the Crane
Control and associated switchgear for an Electric Overhead Travelling
Crane shall be capable of performing any two (2) of three (3) crane
motions operating simultaneously.
 Electrical installation and components (including motors) shall be
designed as per IEC standard and suitable for a design ambient
temperature of 50 C minimum.
 Electrical equipment design shall conform to the Electrical Specification
SP1103 / IEC 60204-32:2008
 Main power supply only is supplied by Contractor. Any other voltages and
earthing (auxiliary power supply) shall be derived by Supplier within its
scope of supply from the incoming main power supply.

Power supply: 415 ± 5% V AC, 50 ± 2% Hz (3 Ph / 3W)

Auxiliary supplies (derived from main power supply):

Contactor coil: 230 V AC (1 Ph + N)

 Circuit breaker low voltage coil: 110V DC

Auxiliary relays: 110V DC

 All motors shall be controlled, protected and isolated within the package.
 All electrical equipment shall be designed for an intermittent duty of up to
150 operations per hour.

3.5.2 Electric motors.

 Electric motors shall confirm to specification SP1119 and DEP

33.66.05.31
 The maximum power requirement of the driven equipment shall be
determined at de driver coupling and shall include all transmission losses.
 Maximum number of starts in one hour for the main motor (hoist) shall be
specified by the Supplier.
 Dual speed motors for Hoist and single speed motors CT and LT shall be
used.

3.5.3 Junction boxes and main disconnect switch box.

 A main disconnect switch box shall be provided by the Supplier, to be

located at grade level. The operating handle of this switch shall have
provisions for being padlocked in the open and closed positions.
 The degree of protection of junction boxes, main disconnect switch boxes,
and any electrical enclosure shall be at least:

.IP22 Indoor air-conditioned area

.IP44 Indoor non air-conditioned area

.IP56 Outdoor open area

 Supplier shall supply all double lock type cable glands on junction boxes,
main disconnect switch boxes and any enclosures.

3.5.4 Cables

 Cables design and minimum cross sections shall be specified according to

cables Specification BS EN 50288-7:2005 and IEC 60502 pt 1 & 2
  For steady state conditions voltage variation shall not exceed +/- 5% of
rated value under normal operating conditions (according to FEM par.
5.2.1.2). For transient conditions (motor start-up), voltage drop shall not
exceed +10%/-20%.
 No bare conductors are allowed. Enclosed conductors, cable drums,
energy chains or festoons shall be used.
 Safety chains shall be provided by Supplier on all festoon cables to
prevent mechanical stress.

3.5.5. Control

 Radio remote control with pendant control as a backup shall be provided.

 Push button control box shall allow low and high speed of motors and
shall be designed so that when pressure is released from the button, the
machinery motion will stop.
 Push button control box type (pendant, fixed, independent from trolley
motion) is indicated on data-sheet.
 Pendant shall be “non-breakable” (high impact plastic) antistatic plastic
with galvanized wire rope suspension.
 An emergency stop pushbutton cutting off control supply for all motions
shall be provided on the control pendant.
 Control box shall be IP56
 Control signals shall be 24V DC.
 When radio control system is specified, Supplier compliance with IEC
61000-2-2 is required.
 Two sets of limit switches shall be provided by Supplier. First one is to
reduce speed (pass to slow speed) for bridge travelling, trolley traverse
and hook lifting/lowering mechanisms. The second one is to stop crane
motions.

4. Environment and Safety.

4.1 Climatic data

Environmental conditions are detailed in SP 2200.

4.2 Hazardous area classification

Hazardous area classification is provided in the individual Data-Sheets.

 When situated in an explosive atmosphere, Supplier shall ensure that no spark (no
contact of steel on steel allowed) can occur during normal use of the equipment.

Rods of limit switches installed in hazardous areas shall be of non sparking

material. Photocell or proximity detectors may also be utilized.

Protection methods for electrical items shall be carried out in accordance with the
content of;

 SP-1107 and shall fulfill the requirements of the relevant part of IEC-
60079.

Protection methods for non-electrical items shall be implemented as per the

requirements of EN-13463.

Marking must be carried out in accordance with ATEX 94/9/CE.

It shall not be assumed that the packaging of individually certified components

makes a certified unit. A third party certification must be provided. The third
party shall be chosen among the Company approved Certifying Agencies.

4.3 Human Factor Engineering (HFE)

HFE requirements are provided in specification; DEP 30.00.60.13 & 20

4.4 Acoustic requirements

Each item shall comply with requirements of specification EN ISO 3744:2010

When the crane (composed of all noisy components of the scope of supply) is in
normal operation and at full load, the maximum sound pressure level at one meter
(SPL(1m)) from the package shall not exceed a value of 75 dB(A).

4.5 Safety Requirements

Safety rules shall conform to BS EN 15011 for overhead crane and for hoists EN
14492-2

5 Inspection and Testing

5.1 General

Inspection and testing shall be in accordance with local safety regulations and the
BS7121-2-7 requirements.
5.2 Classification / Certification

Overhead cranes and hoists are subject to Certification by a Third Party.

5.3 Factory Acceptance Testing(FAT)

Inspection and test at workshop shall be in accordance with the

requirements of applicable Codes or Standards and shall include as a
minimum:

 Checking of dimensions in accordance with general arrangement

drawings.
 Test of limit switches
 Weld inspection for crane girders
 Static test (125% of safe working load)(*).
 Deflection test under safe working load (limited to travelling
cranes) with maximum deflection as specified in paragraph 3.3
 Dynamic test (110% of safe working load) (*) of hoists and/or
cranes crab system. During dynamic test, load lifting along the full
lifting height is not mandatory.
 Speed test
 Routine test of motors

(*) figures given for test load represent minimum requirements. Where
national legislation or local rules call for higher values, Supplier shall
comply with the most stringent values.

5.4 Site Acceptance Tests(SAT)

Before SAT the equipment must be registered in SAP as per PR

1710 and SP2114 for

maintence to be followed.

Field test after erection shall be performed in accordance with

requirements of applicable codes and standards and shall include
as a minimum;

 Weld inspection for LT rails

 Full functional test
 Speed tests
 Checking of controls and safety devices
 Insulation and continuity tests
 Voltage drop to be verified at SWL
 Overload lift tests
 Drop test to verify brake performance
  Static load test (125% of safe working load)
 Dynamic load test (110% of safe working load)
 Control and final test with relevant authorities
 Ex verification

5.5 Material Certification

The following material certificates as defined in EN 10204 shall be

provided;

EN 10204 material certificates types;

Steel structure / girder 2.2

Wheel pins 3.1

Hook 3.1

Rope 3.1

Gears 3.1

6. Guarantees and warranty

6.1 Mechanical guarantees

According to the General Conditions of Purchase and Special

Terms of Purchase, the Supplier shall guarantee that all materials
are new and free from defects.

6.2 Performance guarantee

A +5% tolerance on speeds is permissible (travelling,

traversing and hoisting), in loaded conditions.

7. Name plates

7.1 Nameplates of stainless steel shall be securely attached by

stainless steel fasteners to all major

components of the crane. The Nameplates shall be located

in a position such that they are easily readable.
7.2 All nameplates shall contain the following information which
shall be engraved on to the

nameplates:

 Manufacturer’s name, equipment type and serial number

 Safe working load (SWL)
 Design code/class
 Structural steel grade
 Design temperature
 Serial number
 Year of manufacture of equipment

7.3 The maximum permissible Safe Working Load of the

Crane shall be clearly and visibly marked on the
equipment. The markings may be on a separate plate or
painted directly onto the crane

structure. The letters and numbers shall be on at least two

opposing visible faces of the crane,

and it shall be in both English and Arabic languages.

Letters shall be black and preferably on a white background

and be 75 mm high.

The hook assembly shall also be marked on both sides with

the Safe Working Load of the crane.

8. Painting & Surface preparation

Surface preparation and painting of EOT crane shall be in

compliance with SP1246 part 1 to 5.

If this is not possible, vendor may offer their standard

painting system for approval by the purchaser, but this shall
be at least equivalent to the paint system to SP1246.

Annexure1 Annexure 2