Installation of Rail Line Lubricator in EOT Crane For Rail & Wheels Wear Protection

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1 1121 Installation of Rail Line Lubricator in EOT Crane For Rail & Wheels Wear Protection Kush Jaiswal 1, Shiekh Majhrul Islam 2, Tarkeshwar Chandra 3 1, 2, 3 Student, Bachelor of Engineering, Mechanical Engg. Kirodimal Institute of Technology, Raigarh, Chhattisgarh, INDIA Prakash Kumar Sen 4, Shailendra Kumar Bohidar 5 4,5 Faculty, Department of Mechanical Engineering Kirodimal Institute of Technology, Raigarh, Chhattisgarh, INDIA ABSTRACT There is a simple and direct relationship between steel business profitability and maintenance cost. It take sales of many tons of steel to obtain enough profit. This amount of tonnage varies of course, with each company's product, processing cost, labor cost, unscheduled down time problems machinery repair cost, and various other business cost. With today sglobal economy, steel business profits are typically decreasing and maintenance cost must do likewise. Prolonging machinery operating duration has the same positive business effect as the sales department selling of many tons of steel. In the steel industry, crane is critical to processing steel. Crane maintenance personnel are finding it is better to work smarter than harder. The largest maintenance expenses incurred for modern, fast and long span electric overhead travelling (EOT crane) is incurred for wheel assembly replacement, from an independent survey conducted at the maximizing crane maintenance paybacks specially the number one reason crane wheel are replaced is due to thin flange. If the crane maintenance department can make crane wheel assemblies last longer and additionally do the same to the rail, this is a strategies way to almost change the rules of the game. Today. Because of advance made in lubrication and the general knowledge that a lubrication system is available, crane wheel replacement due to flange wear has become unacceptable to the steel industry. Therefore rail line lubricator installed to the EOT crane to protect the wheel flange and rail line wear. I. WHAT IS CAUSING THE WHEEL FLANGE WEAR? There are many reasons given by maintenance personnel in the steel industry for wheel flange wearing problems. One of the most common reasons is condition of the building and its foundation. Apparently, it is a widespread belief that the crane runway structure is the problem. The exact interaction causing wheel flange wear is not often well explained, and in part, this is due to inaccessibility as the crane is 20 to 30 mtr high, and the dynamic relationship of the building to the crane wheel flange. The wheel flange problem is thus acceptable and tolerated since fixing the building would cost an enormous amount of money that is not available. All are told this is the big picture and this scenario is readily accepted as fact. It has always been this way and it always will be. Not challenging the validity of this scenario has also become the reality. Another reason given for wheel flange wear is it s the rail misalignments. Rail alignments has been instrumented and found to have deviations of an inch or more from being perfectly straight and parallel. Visual inspections of the rails show areas of side of rail head wear. This side of railhead wear is interpreted as confirmation of an out of gauge rail condition that caused the crane wheels to wear the deviant side of the railhead, resulting in wear on the deviant side of the railhead, resulting in wear on the wheel flange. Outage time and/ or money are not available for expensive realignment work. Maintenance personnel are quick to replace wheels when flanges wear out, production resumes soon after, and it becomes a situation that is to be tolerated, at least for the time being. Sometimes it is tolerated far longer than desired. One side of the crane runway is lower than the other side, maintenance personnel also state as a reason for Wheel flange wear. Examining all the wheels on one side of the crane clearly shows the wear being on the same flange, inside or outside, whichever applies. It is accepted as an obvious deduction of the visible wear on wheels, Again it is accepted as a problem of large

1122 magnitude, one the makes it attractive to replace the less costly wheels that jack up and shim all the columns along the side of the building, It is agreed by most to be the reasonable way to do

Research, both theoretical and experimental, has been conducted on these machine elements that made by sliding under significant loads.

2 1122 magnitude, one the makes it attractive to replace the less costly wheels that jack up and shim all the columns along the side of the building, It is agreed by most to be the reasonable way to do maintenance. Maintenance personnel also attribute wheel flange wear to the geometry between the wheel flange and the side of the rail head. Research, both theoretical and experimental, has been conducted on these machine elements that made by sliding under significant loads. As the wheel flange and rail continue to intrusively interact their geometry undergoes changes until an equilibrium state is reached. This is flange and rail wear. Finally, some maintenance personnel claim that the crane is old and out of square, which is also known as diagonal disturb which causing wheel flange wear. The fact that cranes have collided either with the end of the building bumpers or another crane gets cited as a contributor. The apparent belief is that this event can twist the crane out of its original shape in such a manner that it can never be brought back into perfect previous condition again. II. ROOT CAUSE FOR FLANGE WEAR When two metal surfaces are rubbed together, friction is created. The softest metal will wear first, but both surface will wear. From the metallurgical, mechanical and operating factors that affect crane wheel life, stated, the first major factors that affect crane wheel life, stated, the first major factor in wheel/rail wear is the coefficient of friction between the wheel and the rail. between the flange and the rail results in visible pitting, galling and abrasive wear on both the flange and the rail head. These surfaces become highly polished and smooth also it may be bent due to thin flange. III. SOLUTION An effective solution to the issue of crane wheel and rail wear has long been an issue for crane maintenance department therefore it has to develop crane wheel lubrication system. The goal is to reduce the coefficient of friction and therefore prolong the life of the rail and wheels. The lubrication system has been proven in the most arduous of surroundings delivering spectacular results worldwide. The lubrication system is an applications for wear against metal, filling microscopic pores to create smoother surfaces. The lubrication system is easy to maintain. By providing a lubrication system in EOT Crane wheel flange wear and Rail wear can be protected. Rail line lubricator specially designed for auto-lubrication of wheel flanges on slow-moving rail-mounted cranes. However, the system is suitable for all machinery that operates on a rail profile. Fig1. Wheel flange wear and bent. A lower coefficient achieves reduced resistance to rolling, and rail should interface. Friction is needed between the rail head and the wheel tread for traction purpose, but friction between the wheel flange and the sides of the rail head is not desirable. High friction Fig2. Oil tank lubricator for rail & wheel flange wear protection.

3 1123 Fig4: Rail Line lubricator (side view) Fig3. Rail Line lubricator (front view) It uses two lubrication rollers for the left and right flank of the crane rail to evenly apply lubricant. Two lubrication rollers for the left and right flank of the crane rail to evenly apply lubricant. The lubrication rollers run parallel to the crane wheels. Wear is particularly high on Rail and cranes side that do not run exactly parallelthis is the problem that occurs especially when the distance between the rails is very large. The lubricants (Gear oil #220 servo mesh) supply to the lubricant roller is typically provided by central lubricating pump, which is self-operated with rotation of rollers. Progressive metering devices located downstream. The lubricator pin

This lowers and reduces that life expectancy of the wheels and reduces the wear on the rail itself. This lowers repair costs and more importantly, reduces costly downtime.

4 1124 on the metering devices can be used to visual determine if lubricants is evenly flowing. Regular lubrication of rails drastically increases the life expectancy of the wheels and reduces the wear on the rail itself. This lowers and reduces that life expectancy of the wheels and reduces the wear on the rail itself. This lowers repair costs and more importantly, reduces costly downtime. RAIL LINE LUBRICATORS FOR CRANES [Examples of use] Sides of overhead tralvelling rails are lubricated. Two sets (lubricator body + Oil tank) are mounted on a crane. [Effects] Wear of wheel flanges decreases, the replacement intervals are extended, and their lives are extended about 5 times. Since lubricator was installed the wheel flanges wear problem is removed. The maintennace engineers also reports the crane rail does not show wear either. This crane previously made a high-pitched screening noise from the wheel flange and rail contact that offened shop floor personnel. Today the operation is becomes easy and comfort. At jindal Steel & Power Ltd. Maintennace engineers reported that wheel changes due to the flange wear problem was a major problem on their most of the cranes until they implemented flange lubrication. Now they no longer have flange problems and have gone from break- down maintenance to preventive maintenance. They have re-railed the plant with their own forces as they do not have to consume maintenance resources for wheel changes. Fig5.: Lubricator intalled in cranes end carriage lower side. IV. IMPLIMENTATION AND BENEFITS A 40 ton crane that handles slab in a furnace discharging side and also for maintennace of plate mill. Operation historically required replacement of its ten wheels every two years due to flange wear. Fig7.: After installing llubricator wheel flange & rail wear protected. There are many more documented success stories where savings have been recognized through the use of flange lubrication. A reduction in coupling and gearing failure to the long travel bridge drive shafting has also been realized as a result of flange lubrication. The entire drive train benefits from reduced stress when the coefficient of friction is reduced at that crane wheel flange/rail wear. V. CONCLUSION Fig6.: Before installing the lubricator. Lubrication will not heal runway girder deflections, mend deteriorated building foundations, straighten crane rails they are not parallel, make columns on sides of buildings grow taller and level the building, curve the setting of brakes or change their timing, nor cause twisted of deformed cranes to be square again. But lubrication is the method to change the coefficient of friction between the crane wheel flange and the side of the crane rail head.

5 1125 Many of the steel plants who have experienced these problem have availed themselves to lubrication and found that perhaps the runway problems may not have been as severe as first percieved. Perhaps the foundations were not really the problem as suspected. Or perhaps the building have one side a little lower was not the major contributing factor to wheel flange wear as originally theorized. May be the brakes did not really impact the wheel flange wear condition, either. There are many different lubricants, application methods, competing products and manufactures available to solve most, if not all of the wheel flange wear problem. There are many test about the success of these lubrication system. It proven the tests to be applied so that maintennace can do its part in reduecing buisness expenses. It is not accepted crane wheel flange failures in any orgenization, Today, because of the advances made in lubrication system and the general knowledge that lubrication systems are available, Crane wheel replacement due to flange wear has become universally unacceptable to steel plant. REFRENCE 1. From Crane maintenance departmentjindal steel & power ltd Raigarh (C.G) INDIA

Reducing the Structural Mass of a Real- World Double Girder Overhead Crane

Reducing the Structural Mass of a Real- World Double Girder Overhead Crane V.V. Arun Sankar 1, K.Sudha 2, G.Gnanakumar 3, V.Kavinraj 4 Assistant Professor, Karpagam College of Engineering, Coimbatore,