ENERJSA

BANDIRMA-II CCPP
GAS & STEAM TURBINE BUILDING CARANES
250/25/4 TON * 34.80 M.
FUNCTIONAL DESCRIPTION

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Table of contents
1

General
1.1
General Crane Philosophy
1.2
General Control System Philosophy
1.3
Radio Control Handset
1.4
Pendant Handset Control
1.5
Anti-Collision between Cranes
1.6
Hoist limits and brake prove switch
1.7
End limits for Slowdown and Stop
1.8
Floodlights
1.9
Crane Indications and Sounder
1.10
Crane speeds for different operating modes
1.11
Cranes power supply main switch
1.12
Cranes power supply system ( Mains and Heating)
1.13
Earth leakage for 400V
1.14
Phase protection relay
1.15
Intermediate load key switch
1.16
Safety relay
1.17
Cubicle lights
1.18
Crane maintenance sockets
1.19
Monitoring system

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1 GENERAL
This document is a functional description for the smaller cranes at ENERJSA BANDIRMA-II CCPP Bandrma power
station. The purpose of this document is to provide explanation of operator interface to allow the crane to be driven
and recognize the warning indications provided.
1.1

General Cranes Philosophy.

There are two cranes on the same rails. The cranes can be used individually or in master and slave mode.
Each crane has three hoist units on a single trolley. The trolley is running on top of double girder rails.
For each crane, there is three hoists, these are:
Main hook
250t.
Aux hook
25t.
Monorail hook 4t.
Each crane can travel in two motions, these are:
Bridge travel.
Trolley travel.
1.2

General Control System Philosophy.

The main bridge walkway has the electrical control system cubicles mounted on the walkway. Flat form cables from
the bridge cubicles to trolley junction boxes relating to each hoist will be formed in to a moving festoon system.
There are two ways to control the cranes:
Radio control. These can be seen in appendix 1.
Back up pendant control. These can be seen in appendix 1.
With radio control selected, master and slave can be selected for use. With back up pendant, master and slave mode
is not available.
The radio control can be used from anywhere in the same building as the crane. The backup pendant is designed to
be used by a crane operator when he is standing on the lower crane bridge platform in near vicinity of the main
crane control cubicles/main leads cage.
The method of selection between radio or backup pendant is by a plug and socket Exchange at the main crane
cubicles on the crane bridge walkway. This gives a safe and secure selection of the control method for operator
control.
Both radio control and pendant have colour codes for distinguishing the bridge and travel motions, corresponding
colour labels are physically placed on the crane to indicate which direction is which. Colours used are the standart
colours, red & green for trolley and blue and yellow for bridge travel.
Master crane <-> slave crane communications are designed info the control scheme. In tandem mode this provides
cross interlocking of both cranes with each other for safety and limit functions. .e. if the master crane trips (or
reaches an end limit), then the slave crane will follow the control actions of the master, and vice versa.

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Anti collision is provided between the cranes to prevent collision between the cranes when working individual mode.
When the cranes are working in tandem mode, the anti collision interlock is defeated.
There is a tandem cranes operation anti bridge travel speed drift proximity switch. A proximity switch will be fitted to
the master and slave cranes. If the two cranes drift apart from each other too much distance, the proximity switch
and both crane bridge motions will ramp down to a stop.
The cranes will be equipped with a FAST/SLOW speed select function. This function is only available from the radio
handset. Selecting FAST will allow the cranes to travel and hoist at up to full speed. Selecting SLOW will put all the
crane into a micro speed mode, with micro speed the speed is slowed down to a much reduced speed, (typically 5-20
% adjustable from VFD parameters).
Condition monitoring with control pro units. There is one control pro for each hoist (3 off). These three control pro
units communicate with each other to provide load weight information and bridge overload function, as well as
individual hoist overweight protection and other crane status indicators such as safe working period etc. Each hoist
has a transducer to give signal, note this signal is primarily for overweight cutout and does not produce a high
accuracy at low weights.
Only one hoist can be operated at any one time. Bridge and trolley motions are interlockes from each other so that
only one travel motion is possible at one time. Note: bridge or trolley + one off three hoist can operate
simultaneously.
Braking resistors are used to dissipate energy when lowering the hooks, or decelerating the travel motions. The
resistors are house in dedicated cubicles as part of the cubicle row.
All crane electrical motorsa are driven and protected by variable frequency drives (VFD) CALLED Schneider/ ATV 71
These VFD provide the over current protection fort he motors. All motors are with over temperature sensors that will
cut the motion if an over temperature is detected. Where necessary, motors are fitted with cooling fans and anti
condensation heating.

1.3

Radio Control Handset.

The radio handset has a key that must be inserted into the handset before the handset will transmit any signals to
the crane(s).
When using the crane in the radio handset mode, the driver has 2 off joystick controllers that can be pushed to select
the desired crane function (bridge move, trolley move, and hoist selected move).
There is a red emergency stop (E-STOP) pushbutton on the side of the radio handset, this must be pulled out before
the crane will START for use. The START pushbutton for energising the crane main contactor and allowing power to
the variable frequency drives. Note: after pulling out the E-STOP pushbutton, the start has to push momentarily until
yellow LED indicator on the handset goes GREEN flashing, then released and pressed again to start the crane. This is
to guard against accidental crane startup.
There is a horn pushbutton for sounding the audible warning at any time by the crane operator.
The floodlights can be controlled from the radio handset. A momentary pushbutton switches them ON if the
pushbutton is pressed, the same pushbutton has to be pressed continuously for more that 3 seconds to switch the
floodlights OFF.

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To put the master handset into tandem mode, a key from the slave handset must be removed from that handset and
put into the master handset, this will enable tandem mode to be used, and disable the slave handset. This key is only
with-draw able in the OFFposition to prevent accidental operation of the slave crane when in tandem mode, i.e. the
key is locked in the master handset and not available to put into the slave radio handset.
On the master crane radio handset, (A) master / (A+B) tandem / (B) slave selector switch is used when in tandem
mode to select which crane(s) are wanted to be moved. In tandem mode it is possible to drive one crane main hook
or trolley on its own. This allows for fine alignment of the payload on the two hooks.
A lamp test pushbutton is provided to allow the crane indicators and beacons to be tested.
The radio handset is equipped with a FAST / SLOW speed select function.

1.4
Pendant Handset Control.
The pendant is to be used from either the main leads Access cage or the lower bridge platform directly above the
main leads cage.
The pendant handset has a Control OFF / ON key switch to enable the pendant for use. Double pressure pushbutton
for RAISE / LOWER: TROLLEY LEFT / RIGHT and BRIDGE FORWARD / REVERSE allow control of the speed with an
electronic potentiometer type of control.
There is a red emergency stop pushbutton on the pendant handset, this must be pulled out before the crane will
START for use. The START pushbutton for energising the crane main contactor and allowing power to the variable
frequency drives.
The start pushbutton also sound the crane horn.
A selector switch to select between the 250t/25t/4t hoist is provided.
The floodlights can be controlled from the backup pendant. A momentary pushbutton switches them ON if the
pushbutton is pressed, the same pushbutton has to be pressed continuously for more that 3 seconds to switch the
floodlights OFF.
A lamp test pushbutton is provided to allow the crane indicators and beacons to be tested.
The pendant is equipped with a FAST / SLOW speed select function.
1.5
Anti Collision between Cranes.
Anti collision sensors on both cranes will prevent accidental collision between the two cranes. The sensors will detect
the cranes when they come into close proximity to each other, they will slow thw crane first, and then stop the crane
at a predetermined distance.
A procedure to drive the cranes closer towards each other in preparation for tandem use is provided, this is as
follows: Om the main cubicle door (20SMM01/02), turn the key switch marked -S50 to ON, at the same time pres
-S51 to allow the anti collision system to be bypassed and drive the two cranes together with either radio controller
joystick sor pendant pushbuttons.
When master / slave mode is selected, anti collision is disabled. When cranes go back to be using in solo mode, the
anti collision is automatically re-enabled.

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1.6
Hoist Limits and brake prove switch.
For the 250t hoist, a rotary hoist limit switch is provided for raise stop, raise slowdown and lower slowdown and
lower stop.
An intermediate hoist limit for beam connected when in tandem mode is provided, prevent beam from being able to
hit the bottom of the crane girders.
250t Hoist brake prove switches for both the hoist brakes are used to interlock into the control circuit to prevent
hoisting operation if they do not give a positive feedback signal within a short time. The brake switches are solo
logged in the monitoring system.
Hoist ultimate limits are provided for all hoists, 250t, 25t and 4t.
1.7
End limits for Slowdown and Stop.
Magnet switches (no physical moving parts) for bridge end of travel and slowdown are provided. (master crane -S21
and -S22, slave crane -S11 and -S12).
Magnet switches (no physical moving parts) for trolley end of travel and slowdown are provided (-S11.-S21, -S12 and
-S22).

1.8
Floodlights.
Six off 400W HPI type floodlights are fitted to the crane. These floodlights maintained via a hinged hatch opening on
the crane bridge walkway. The floodlights are mounted on a frame that allows them to be pulled up to walkway level
(from the bottom of the main girders) for maintenance. The floodlights are controlled from either the radio handset
or the backup pendant.
1.9
Crane Indications and Sounder.
Crane indicator-Fault. (RED)
A red flashing light is used to indicate a crane fault. Crane fault can be for the following reasons:
Phase fault relay(s) detects problem
Any hoist (A: 250t, B: 25t or C: 4t) is overloaded.
B hoist motor overload trip. (*note 2 x hoist motors with one gearbox)
B hoist brake overload trip. (*note 2 x hoist brakes with one gearbox)
Trolley motor overload trip.
Bridge motor overload trip.
Crane indicator-Eart fault. (YELLOW)
A yellow flashing light is used to indicate an Earth fault. Earth fault is either the mains or control earth leakage relays
tripped. To reset, press the alarm pushbutton on the radio or the back up control station.
Crane indicator-Control ON. (GREEN)
A green flashing light is used to show the crane main contactor is energized and the crane is enables to move.
Crane indicator- Radio ON. (CLEAR)
A clear flashing light is used to show the crane radio handset is selected by use. (i.e. the radio system is plugged in to
the radio/pendent changeover sockets).

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Crane alarm sounder.

A warning sounder is provided that the crane operator can use to sound the warning sounder by pressing the alarm
pushbutton on the radio handset or the backup pendent.
1.10
Crane speeds for different operating modes.
The control system controls the crane motions with variable frequency drives (VFD), in different operating modes,
there are different speeds available. These are as follows:
Normal crane mode (nominal speeds):
250t Hoist:
2.5M/min.
25t Hoist:
5,2M/min.
4t Hoist:
8,0M/min.
Bridge:
25M/min.
Trolley:
25M/min.
Extended speed Range crane mode, only 250t hoist (ESR), available with light load on hook:
Hoist: 3.0M/min.
Tandem mode (only available with Radio control). In tandem mode second speed limit function is enabled on bridge
and trolley ATV 71 units:
Bridge: 12,5M/min. (This is adjustable by Bridge ATV 71 inverter parameter).
Trolley: 12,5M/min. (This is adjustable by Trolley ATV 71 inverter parameter).
Micro speed mode (only available with Radio control):
Hoist (only 250t hook) : typically 10% (This is adjustable by ATV 71 Converter parameter).
Bridge: typcally 10% (This is adjustable by Bridge ATV 71 Converter parameter).
Trolley: typically 10% (This is adjustable by Trolley ATV 71 Converter parameter).
1.11

Cranes power supply main switch.

Crane main switch.

At ground flor level, an enclosure is provided to allow isolation of the crane power supply (400V) and heating supply
(230Vac). It is assumed that the 400V main supply will be switched off when the crane is not used for a length of
time, and the heating supply will remain on all the time unless it specifically has to be switched off for maintenance.
These 400Vac 3 phase and 230Vac single phase heating supply are different cables feding into this main switch
enclosure (from the ENERJSA main distribution).
1.12 Cranes power supply system (Mains and Heating).
Crane power supply busbars.
The two 250t crane share a common busbar power system. The feeding point on the busbars is approximately in the
middle of the length of the bars. The power supply bars have 400V L1,L2,L3 and PE. The busbar is rated at 630A. The
bus bar construction is aluminum stainless steel construction; this is best selection for long periods of non use as
might be expected in a power station application like Bandrma. Double collectors are used for extra security of
supply for the cranes.
Crane heating supply busbars.
The two 250t crane share a common busbar heating system. The feeding point on the busbars is approximately in
the middle of the length of the bars. These heating supply bars have 230Vac and neutral. The busbar is rated at 100A.
The bus bar construction is aluminum stainless construction, this is best selection for long periods of non use as
might be expected in a power station application like Bandrma. An indication on the main cubicle face will show if
the heating barsa re energized and switched on at the main cubicle.

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1.13 Earth leakage for 400V

Earth Leakage for main supply 400V.
L1, L2 & L3 are taken through a current transformer loop connected to the earth leakage relay. If the summed
current of all three phases is detected to show an earth leakage fault, then the relay will trip and stop all crane
functions with the crane main line contactor de-energising.
The reset function for the earth leakage protection is to press the alarm pushbutton on the radio or the backup
pendant.
1.14 Phase protection relay.
The phase relay checks for under voltage and phase rotation. If either is detected the crane main contactor is
immediately de-energised and all motions will stop and the brakes will apply. An indicator will signal phase fault.
1.15 Intermediate load limit key switch (250t / 100t).
A key switch is provided inside the main cubicle to allow the SWL of the crane to be preset to an intermadiate load
(weight) limit. This key switch is wired to the main control pro unit, however the overall function is to restrict the
bridge weight.
1.16
Safety relay.
A safety relay is fitted for the emergency stops and the ultimate limits. Also if the Access ladder is not in the safe
position, the crane cannot be started.
1.17
Cubicle lights.
Electronic type cubicle lights are provided internal cubicle illumination for easier maintenance. The cubicle lights are
switched ON when the corresponding cubicle door is opened.
1.18 Crane maintenance sockets.
230Vac equipment and maintenance sockets are provided on the crane at the following places:
Inside the cubicles, 2 off similar to below for plugging in laptop or similar equipment.
On the end of the bridge main cubicle 1 off 230Vac socket like below for maintenance hand tools.
On the trolley junction box 1 off 230Vac socket like below for maintenance hand tools.
Inside the cubicle, 1 off UK type socket for laptop similar to below (for BVS UK, and in case commissioning with UK
equipment laptop).
Note all sockets are protected with RCBO residual current circuit breakers (to provide earth leakage protection for
human protection).
Note: the combined power available to the cubicle sockets is 5000W. This is based on the crane floodlights being
switched OFF.
1.19 Monitoring system.
An industrial PC is fitted to the cubicle face. This provides a monitoring and logging system for key inputs and process
variables (speed, hook weights & hook heights). The industrial PC has a wireless modem so that the PC can be GSM
and interrogated remotely. The PC on the crane can be accessed from any place in the world via internet. The
remote operator uses a special software to connect to the relevant screens of the Crane application on the PC.
The connection of remote operation requires a valid password to prevent unauthorized accesses. The industrial PC
is running a software PLC emulator which interfaces to a profibus input rack to collect discrete digital signals. The
profibus also interfaces to all crane VFD to collect information also. The control pro information is also collected via a
RS232 to profibus adaptor.

______________________________________________________________________________
vedik Organize Sanayi Blgesi Aa leri Sitesi 1366 (Eski 598). Sok. No: 14 vedik / ANKARA
Tel.: +90 0312 394 42 86

Fax.: +90 0312 394 42 87

e-mail : info@genosis .com.tr

______________________________________________________________________________
vedik Organize Sanayi Blgesi Aa leri Sitesi 1366 (Eski 598). Sok. No: 14 vedik / ANKARA
Tel.: +90 0312 394 42 86

Fax.: +90 0312 394 42 87

e-mail : info@genosis .com.tr