Synopsis of Portal Crane Drives and Controls Retrofit

  • Situation: A leading North American steel supplier retrofitted two 75T mobile gantry cranes. The LeTourneau MRG 500 and GC 500 cranes are used to load/offload, import/export steel slabs and steel coils from ocean-going vessels in Hamilton, Ontario.
  • Issues: Overall performance improvement, with specific focus on eliminating live electrical hazards; increasing safety of operations; reducing the cost of on-going maintenance going forward; and eliminating the problem of obsolescence and lack of technical service and support.
  • Requirement: Drives and controls retrofit that included:
    • Replacing existing motor-generator equipment with new digital DC drives; replacing relay logic controls with new PLCs, motion controllers, and HMIs; providing new fail-safe controls for Boom and Hoist equipment; providing new emergency braking systems for Boom and Hoist drums; providing a new operator cab complete with new controls and instrumentation; providing demolition and installation engineering, commissioning, and training.
Portal Crane—Drives and Controls Retrofit
  • Brock Solutions' Role: Complete the retrofit while addressing challenges such as schedule limitations (conversion had to be completed in a 14-week time frame between shipping seasons; “Soft Power” (Drive and Control system had to be robust to withstand Voltage and Frequency fluctuations due to “Soft Power” supply from a diesel generator); Supplier Coordination (operator cabs that typically take >12 weeks to deliver were supplied in less than 8 weeks); Short Start-Up (less than 1 week/crane); Confined Space (limited space for new equipment); and Weather Conditions (work through Canadian winter).
  • Technology: Allen-Bradley—SLC 5/05 and SAF—SAFphire controllers. SAF DD312 drives. Johnson Industries—Disc Brakes. Exor—HMI.
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