NEW BONG ESCAPE 

Oct. 2012

TRAINING MANUAL

Vol. I: Stoplog and gantry crane

Stoplogs & gantry crane – General informationInformation about the sheet

The Operation and Maintenance Manual is the actual documents, not these sheets

These slides are for training purpose and

are not the basis for service and maintenance

and not definitive

can often only be described in words

serve as a reminder

may not be passed on to third parties

The documentation will not be updated and makes no claim to be “as built” and complete.

No claims of any kind can be raised from these training slides, not even if the information they contain is correct and action is taken based upon these slides

The slides will be provided at request of course paticipant

Copyright by Andritz Hydro

Training- General InformationTargets of this training

Better understanding of the NBE_ Stoplogs and gantry crane

Design

Function

Maintenance

Getting an overview of the design

Finding new question_ and the answers

Hear the focus of the designer

Talking with the “design”

Training – General InformationContent for the Stoplogs & Gantry crane

1. Stoplogs1.1 General Description1.2 Detailed description of Stoplogs

2 Intake 1000kN gantry crane2.1 General Description2.2 Technical Data2.3 Detailed description of intake gantry

crane

3 Draft tube 300kN gantry crane3.1 General Description3.2 Technical Data

3.3 Detailed description of draft tube gantry crane

4 Operation and Maintenance

Training – General InformationStoplogs General Description

The stoplogs provided by us include the intake stoplogs and draft tube stologs.The stoplogs are provided to seal off the turbine waterway.The intake stoplogs include five segments of gate.It is of vertical lift and fixed wheel type with downstream skin plate and seals.The skin plate is reinforced by horizontal and vertical members welded to skin plate.The draft tube stoplogs include four segments of gate.

Technical DataClear width: 11.00 mHeigth: 13.040m (between sill and lintel)Span: 11.5 mNumber of sets: 4Number of stoplogs per set: 5.Height of each stoplogs: 2.650 m

Training – General InformationDetailed description of intake Stoplogs

Intake stoplogsassembly

Intake embedded arrangement andSide guide device

Training – General InformationDetailed description of Intake Stoplogs

Intake lower element stoplogs

Intake upper

element stoplogs

Training – General InformationDetailed description of Intake Stoplogs

Intake stoplogs sealing device

Training – General InformationDetailed description of draft tube Stoplogs

Draft tube stoplogsassembly

Draft tube embedded arrangement andSide guide device

Training – General InformationDetailed description of draft tube Stoplogs

Draft tube element stoplogs

Draft tube stoplogs sealing device

Training – General InformationIntake 1000kN gantry crane- General Description

The gantry crane mainly consists of trolley, gantry fame, crane traveling mechanism, power supply system for gantry crane, rail clamp system, aerovane, cabin, rail system and electrical equipment.The spillway gantry crane is mounted on the El.255.4m, and used to lift the upstream stoplog.

Main features1.The hoist has one hook, and the wire rope shall be winded on the drum with one layer.2.Frequency conversion speed adjustment is adopted for the trolley traveling mechanism and crane traveling mechanism.3. The cable drum is adopted as the crane power supply.4. The PLC control technical.

Training – General InformationIntake 1000kN gantry crane- Technical Data

The gantry crane classification group (FEM): A3

Classification group of main hoist mechanism: M3

Classification group of trolley travel mechanism: M3

Classification group of crane travel mechanism: M3

Rated lifting capacity of main hoist: 1000kN

Lifting height for main hoist (above rail/total): 6.5/32m

Trolley travel speed: 0.48~4.8 m/min

Wheel dia. for the trolley travel: f500mm

Rail Center of trolley： 5.3mmCrane travel speed: 1.984~19.84m/min(fastly)

0.992~9.92m/min(slowly)Wheel dia. for the crane travel: f500mmSpan of crane: 3.5mType of rail for the crane: QU80Power supply: 400VA.C, 3-ph,50Hz

Training – General InformationIntake 1000kN gantry crane- Detailed description of intake gantry craneThe upsteam gantry crane mainly consists of trolley, gantry fame, crane travel mechanism, power supply system for crane, rail clamp system, aerovane, cabin, rail system and electrical equipment.(Please refer to Dwg. D17-0000)

TrolleyTraveling above the superstructure of gantry frame, the trolley main consists of hoist, trolley traveling mechanism; trolley frame, machine house and ladder, etc. (Please refer to Dwg. D17-1000)

1. Hoist2. Trolley frame3. Trolley traveling mechanism (Dwg. D17-1C00)4. Machine house

Training – General InformationIntake 1000kN gantry crane- Detailed description of intake gantry craneGantry frame (Dwg. D17-2000)Gantry frame is the important structure of the whole crane. Gantry frame mainly consists of main beam, end beam, gantry leg, middle cross girder, lower across beam, trolley rail, platform, etc. The gantry frame was pre-assembled in workshop, and shall be divided into parts for transportation and shall be assembled into a whole by bolts at site.The high strength bolted friction-type is for the connection of end beams and middle cross girder.The normal bolt is for the connection between legs and bottom across beam.

Training – General InformationIntake 1000kN gantry crane- Detailed description of intake gantry craneCrane traveling mechanism (Dwg. D17-3000)The structure of driving device of crane traveling mechanism is of three in one (the motor, brake and reducer are assembled in one device). Four sets of bogies are equipped for the crane traveling mechanism, and all are driving bogies. Each bogie has two wheels.Each side of gantry crane symmetrically arranges two bogies. The main characters are as- 8 -following:

Training – General InformationIntake 1000kN gantry crane- Detailed description of intake gantry craneRail (Dwg. D17-A000) Rail system mainly consists of rail, rail backplate, crane bumper stop etc. The crane bumper stops are installed at both ends of the rail.

Training – General InformationIntake 1000kN gantry crane- Detailed description of intake gantry cranePower supply system for crane (Dwg.D17-5000)The power supply system for crane is provided at the downstream of gantry crane. It mainly consists of cable drum, supports, etc.

Training – General InformationIntake 1000kN gantry crane- Detailed description of intake gantry craneSafety and protection device1.Hydraulic rail clamp and Mounted device2. Wind speed indicator3. Limiting Device

Training – General InformationIntake 1000kN gantry crane- Detailed description of intake gantry craneElectrical equipmentElectrical component1.Main hoist mechanism1.1.Main hoist mechanism is driven by one YZP type frequency converting motor 1.2. One ACS800 family frequency converter manufactured by ABB Company is adopted for speed adjustment 1.3. An electro-hydraulic thruster brakes are provided for motor braking of main hoist in addition to working braking of frequency converter.2. Trolley travelling mechanism2.1. Trolley travelling mechanism is driven by two frequency converting motors 2.2. One ACS800 frequency converter manufactured by ABB Company is adopted for speed adjustment. 2.3. One brake is integrated with each motor 3. Crane travelling mechanism3.1. Grane travel mechanism is driven by four YP2 type frequency converting motors.3.2. One ACS800 family frequency converter manufactured by ABB Company is adopted for speed adjustment .3.3. One brake is integrated with each motor .

Training – General InformationIntake 1000kN gantry crane- Detailed description of intake gantry crane

Principle of electrical system1.Power distribution system(Please refer to Dwg. D17-8001)Q1 is the main circuit breaker of general supply, which function is for isolation and protection. K1 is the main contactor, all control buttons are on cubicle door. Button SB1 is for switch-on, while SB4 is for switch-off. When K1 is switch-on, power is supplied to all mechanism. Q3 is for an over current protecte brekear for TC2, and the control power supply is isolated from load by the transformer TC2. Q2 is for an over current protecte brekear for TC1, and the lighting power from transformer TC1 is independents of the drive power and the control power to ensure the crane lighting system working well when some mechanism on inspecting. The drive power is supplied to transducers.

Training – General InformationIntake 1000kN gantry crane- Detailed description of intake gantry crane

2.Main Hoist system (Please refer to Dwg. D17-8002)2.1.Operation mode of the hoist mechanism is frequency conversion（ABB，ACS800）. For using this mode the hoist mechanism should start smoothly，have high performance of speed regulate, run on low speed stability for long-term. 2.2. There are two pairs of output contacts of relays: 1KA7 serves as FAULT; 1KA8 serves as BRAKE CTRL.2.3. There are a raise limit and lower limit for main Hoist. 3.Trolley travelling system(Please refer to Dwg. D17-8003)3.1. Operation mode of The trolley travelling mechanism is frequency conversion（ABB，ACS800） .3.2. There are upstream limit and downstream limit for trolley. Each motor has a overheat protector.4.Crane travelling system (Please refer to Dwg. D17-8004)4.1. Operation mode of the crane travelling mechanism is frequency conversion（ABB，ACS800）4.2. There are left limit and right limit for traveling. Each motor has a overheat protector.

Training – General InformationIntake 1000kN gantry crane- Detailed description of intake gantry crane

5.PLC system (Please refer to Dwg. D17-8008)All functions of the crane are realized by the PLC. This crane uses S7-300 PLC controller made by SIEMENS.6.Lighting system (Please refer to Dwg. D17-8006)The lighting box in the hoist shelter as a main unit, with lamps EL3、EL4 lighting for the hoist shelter，lamps EL5、EL6 lighting for erection bay.Lamps EL9~EL11 lighting for platform, Q6~Q8 are circuit breakers which are for short-circuit and over current protection for each circuit loop. 7.Loading and opening monitoring system (Please refer to Dwg. D17-8008)7.1.A load sensor is set for main hoist . The signal of the sensor is transferred by transmitter -1TA to 4~20MA and sent to PLC. The display panel of the load limiter can display the load weight of main hoist. When the load is 90% of rated load, PLC sends warning signals, when the load is 110% rated load, it will send signals to stop hoist. The PLC system manages the load protection of the crane uniformly.7.2.A height sensor is set for main hoist mechanisms. The signal of the sensor is transferred to PLC. The display panel of the height limiter can display the hoist height of main hoist.

Training – General InformationDraft tube 300kN gantry crane- General Description

The gantry crane mainly consists of hoist, gantry fame, crane traveling mechanism, power supply system for gantry crane, rail clamp system, aerovane, cabin, rail system and electrical equipment.The spillway gantry crane is mounted on the El.259.9m, and used to lift the downstream stoplog.

Main features1. The hoist has one hook, and the wire rope shall be winded on the drum with one layer.

2. Frequency conversion speed adjustment is adopted for the crane traveling mechanism.

3. The cable drum is adopted as the crane power supply.

4. The PLC control technical.

Training – General InformationDraft tube 300kN gantry crane- Technical Data

The gantry crane classification group (FEM): A3

Classification group of main hoist mechanism: M3

Classification group of crane travel mechanism: M3

Rated lifting capacity of main hoist: 300kN

Lifting height for main hoist (above rail/total): 6/36m

Hoist speed: 0.48~1.91m/min

Crane travel speed: 1.984~19.84m/min(fastly)

0.992~9.92m/min(slowly)

Wheel dia. for the crane travel: f500mm

Span of crane: 3.5m

Type of rail for the crane: QU80

Power supply: 400VA.C.,3-ph,50Hz

Training – General InformationDraft tube 300kN gantry crane- Detailed description of draft tube gantry craneThe downstream gantry crane mainly consists of hoist, gantry fame, crane travel mechanism, power supply system for crane, rail clamp system, aerovane, cabin, rail system and electrical equipment.(Please refer to Dwg. D16-0000)

Hoist1.Operating principle and characters2. Constitution of main components

Training – General InformationDraft tube 300kN gantry crane- Detailed description of draft tube gantry craneMachine houseMachine house protects main hoist against rain. The machine house equips with door, window and base.

Training – General InformationDraft tube 300kN gantry crane- Detailed description of draft tube gantry craneGantry frame (Dwg. D16-2000)Gantry frame is the important structure of the whole crane. Gantry frame mainly consists of superstructure, gantry leg, middle cross girder, lower across beam, platform, etc.The gantry frame was pre-assembled in workshop, and shall be divided into parts for transportation and shall be assembled into a whole by bolts at site. The high strength bolted friction-type is for the connection of end beams and middle cross girder. The normal bolt is for the connection between legs and bottom across beam, and between main beam and legs.

Training – General InformationDraft tube 300kN gantry crane- Detailed description of draft tube gantry craneLadder, Handrail and Platform (Dwg. D16-6000)Platform, ladder, handrail shall be welded to gantry frame at site according to relative drawings.

Training – General InformationDraft tube 300kN gantry crane- Detailed description of draft tube gantry craneCrane traveling mechanism (Dwg. D16-3000)1.Operating principle and characters2. Constitution of main components

Training – General InformationDraft tube 300kN gantry crane- Detailed description of draft tube gantry craneRail (Dwg. D16-A000)Rail system mainly consists of rail, rail backplate, crane bumper stop etc. The cranebumper stops are installed at both ends of the rail.

Training – General InformationDraft tube 300kN gantry crane- Detailed description of draft tube gantry cranePower supply system for crane (Dwg.D16-5000)The power supply system for crane is provided at the upstream of gantry crane. Itmainly consists of cable drum, supports, etc.

Training – General InformationDraft tube 300kN gantry crane- Detailed description of draft tube gantry craneSafety and protection device1. Handle rail clamp and Mounted device2. Wind speed indicator3. Limiting Device

Training – General InformationDraft tube 300kN gantry crane- Detailed description of draft tube gantry craneElectrical equipmentElectrical component• 1.Main hoist mechanism

1.1.Main hoist mechanism is driven by one YZP type frequency converting motor 1.2. One ACS800 family frequency converter manufactured by ABB Company is

adopted for speed adjustment 1.3. An electro-hydraulic thruster brakes are provided for motor braking of main hoist

in addition to working braking of frequency converter. 2. Crane travelling mechanism2.1. Grane travel mechanism is driven by four YP2 type frequency converting motors.2.2. One ACS800 family frequency converter manufactured by ABB Company is

adopted for speed adjustment .2.3. One brake is integrated with each motor

Training – General InformationDraft tube 300kN gantry crane- Detailed description of draft tube gantry crane

Principle of electrical system1.Power distribution system(Please refer to Dwg. D16-8001)Q1 is the main circuit breaker of general supply, which function is for isolation and protection. K1 is the main contactor, all control buttons are on cubicle door. Button SB1 is for switch-on, while SB4 is for switch-off. When K1 is switch-on, power is supplied to all mechanism. Q3 is for an over current protecte brekear for TC2, and the control power supply is isolated from load by the transformer TC2. Q2 is for an over current protecte brekear for TC1, and the lighting power from transformer TC1 is independents of the drive power and the control power to ensure the crane lighting system working well when some mechanism on inspecting. The drive power is supplied to transducers.2. Main Hoist system(Please refer to Dwg. D16-8002)2.1.Operation mode of the hoist mechanism is frequency conversion（ABB，ACS800）. For using this mode the hoist mechanism should start smoothly，have high performance of speed regulate, run on low speed stability for long-term. 2.2. There are two pairs of output contacts of relays: 1KA7 serves as FAULT; 1KA8 serves as BRAKE CTRL.2.3. There are a raise limit and lower limit for main Hoist.

Training – General InformationDraft tube 300kN gantry crane- Detailed description of draft tube gantry crane

3. Crane travelling system(Please refer to Dwg. D16-8003)3.1. Operation mode of the crane travelling mechanism is frequency conversion（ABB，ACS800）3.2. There are left limit and right limit for traveling. Each motor has a overheat protector.4. PLC system(Please refer to Dwg. D16-8005)All functions of the crane are realized by the PLC. This crane uses S7-300 PLC controller made by SIEMENS.5.Lighting system(Please refer to Dwg. D16-8006)The lighting box in the hoist shelter as a main unit, with lamps EL3、EL4 lighting for the hoist shelter，lamps EL5、EL6 lighting for erection bay.Lamps EL9~EL11 lighting for platform, Q6~Q8 are circuit breakers which are for short-circuit and over current protection for each circuit loop. 6.Loading and opening monitoring system(Please refer to Dwg. D17-8005)6.1.A load sensor is set for main hoist . The signal of the sensor is transferred by transmitter -1TA to 4~20MA and sent to PLC. The display panel of the load limiter can display the load weight of main hoist. When the load is 90% of rated load, PLC sends warning signals, when the load is 110% rated load, it will send signals to stop hoist. The PLC system manages the load protection of the crane uniformly.6.2.A height sensor is set for main hoist mechanisms. The signal of the sensor is transferred to PLC. The display panel of the height limiter can display the hoist height of main hoist.

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