- Apr 22, 2022
- Case Studies
5 sets EOT Cranes Applied in Pakistan Steel Plant
Yuantai Crane delivered five double girder EOT cranes to a new steel plant in Pakistan, consisting of one 25-ton magnet crane and four 15-ton hook cranes for efficient lifting.
Industry Background and Customer Profile
The customer is a major steel plant operator in Pakistan. They produce billets, slabs, and finished steel products for domestic and export markets. Steel plants require robust material handling solutions. They lift molten metal using ladle cranes. They move steel billets with billet handling cranes. They transfer scrap with magnet cranes. They handle bulk scrap with grab cranes. This client needed a complete set of EOT overhead cranes to support their new facility.
Customer's Material Handling Needs
The new steel plant needed efficient, reliable cranes for heavy lifting tasks. The main requirements were:
- Ladle Handling: Two 30/10 ton double girder ladle cranes. They needed to lift and tilt ladles filled with molten steel up to 30 tons. They also needed a 10 ton auxiliary capacity for cleaning and maintenance.
- Billet Handling: One 12 ton double girder crane. It would move hot steel billets from the furnace to rolling mills and storage yards.
- Scrap Charging: One 12/5 ton double girder magnet crane. It would lift 12 tons of ferrous scrap during furnace charging. The 5 ton auxiliary capacity would handle scrap sorting tasks.
- Bulk Scrap Feeding: One 12 ton double girder grab crane. It would scoop and transport large volumes of scrap to the furnace charging station.
- High Duty Cycle: All cranes needed to operate continuously in a harsh, dust-laden environment. They required minimal downtime for maintenance and repair.
- Precise Control: Operators needed precise speed regulation. This was essential for safe ladle tilting and accurate scrap placement.
Challenges Before Using Yuantai's EOT Cranes
1. Outdated Lifting Equipment
Before Yuantai's EOT crane delivery, the plant used older cranes with limited capacity. Ladle transport relied on 20 ton units. They lacked a 10 ton auxiliary hook. Operators had difficulty balancing loads. This caused safety risks and slowed production.
2. Insufficient Scrap Handling
The plant's previous scrap cranes had low lift height. They could not directly feed the electric arc furnace. Workers manually transferred scrap from ground level. This process was laborious and dangerous. It created production delays during peak hours.
3. Frequent Downtime and Maintenance
Older cranes suffered from frequent breakdowns. Their control systems were obsolete. Wire ropes and magnet assemblies wore out quickly under heavy cycles. The plant could not meet daily production targets due to unplanned shutdowns.
4. Limited Precision and Safety Features
Operators lacked precise speed control. Hoists had single-speed motors. Cranes did not have dual-speed lifting modes. This made ladle tilting jerky. Scrap drop zones were inaccurate. Safety features like overload protection were missing. This increased risk of accidents.
Yuantai's EOT Crane Solution
Yuantai designed and delivered five double girder EOT cranes. Each crane matched specific lifting tasks. The solution included:
- Two 30/10T Ladle Cranes with A7 duty class
- One 12T Billet Handling Crane with A6 duty class
- One 12/5T Scrap Charging Magnet Crane with A7 duty class
- One 12T Double Girder Grab Crane with A6 duty class
Design Features of Ladle Cranes (30/10T)
- High Duty Class A7: Suitable for continuous, heavy-duty lifting. It handles molten ladles up to 30 tons safely.
- Dual Hook System: Main hook (30T) for ladle transport. Auxiliary hook (10T) for supporting maintenance tasks.
- Intelligent Tilt Mechanism: Hoist motor supports slow and fast tilt speeds. Precision controls ensure smooth ladle pouring.
- Heat-Resistant Components: Trolley and hoist motors have special cooling fans to withstand high temperatures near ladle areas.
- Enhanced Safety Devices: Overload limiter, upper and lower limit switches, emergency stop button, and anti-sway system.
Design Features of Billet Handling Crane (12T)
- Duty Class A6: Handles hot billets in rapid transfer cycles.
- High-Temperature Resistant Rope: Special wire rope rated for 1200°C. Suitable for hot billet environments.
- Precision Speed Control: Dual-speed hoist and trolley operation. Allows slow positioning of billets onto roller tables.
- Auto-Positioning Control: Encoder-based system for exact billet placement. It reduces manual realignment.
- Compact Trolley Design: Ensures smooth travel along tight workshop aisles.
Design Features of Scrap Charging Magnet Crane (12/5T)
- Primary Magnet Capacity 12T: Lifts bulk ferrous scrap during furnace charging. The magnet core uses high-energy Neodymium to maximize lift capacity.
- Auxiliary 5T Hook: For auxiliary scrap sorting and small equipment handling.
- Duty Class A7: Designed for frequent magnet on/off cycles. It supports rapid charge/discharge operations.
- Closed-Loop Control: Magnet current is regulated to match scrap density. Prevents magnet burnout and reduces energy consumption.
- Dust-Proof Housing: Encases electromagnetic coils to protect against steel dust and debris.
Design Features of Grab Crane (12T)
- Duty Class A6: Suitable for handling scrap with grab buckets in moderate cycles.
- Hydraulic Grab Assembly: Oil-powered grab arms open and close with high force. It scoops bulk scrap from ground piles.
- Precision Depth Control: Sensors on grab arms detect pile height. Ensures consistent grab depth and avoids overload.
- High-Strength Grab Bucket: Wears-resistant steel plates. Handles abrasive materials without damage.
Installation and Commissioning Process
Yuantai coordinated closely with the Pakistan steel plant's engineering team. Key steps included:
1. Site Survey and Layout Confirmation
Before any equipment arrived, our engineers inspected the facility to ensure that all important dimensions and utilities were correct. They measured the workshop's length, width, and clear height. The runway beam positions were designated in relation to the production lines and access lanes. Power supply sites, including three-phase outlets and control panel locations, were mapped. We verified that the runway columns would not interfere with existing pipes or ductwork. This step also involved a study of floor flatness and load-bearing capacity. The end result was a thorough plan drawing depicting crane placements, trip limitations, and cable routing. By sharing these drawings with the plant's civil, mechanical, and electrical teams, we secured scope alignment and avoided site problems during installation.
2. Factory Acceptance Testing (FAT)
Factory Acceptance Testing (FAT) took place at Yuantai’s manufacturing plant under full-load conditions. Technicians assembled each crane bridge, hoist, trolley, and control panel. They then ran simulated workload cycles matching the steel plant’s specified daily usage. The dual-speed hoist modes were tested at both low and high speeds. We activated anti-sway controls and measured residual swing angles. Meltdown protection—designed to cut power if motor temperatures rose above safe levels—was also verified.
3. Packing and Shipping
Protecting heavy equipment during transit is critical to avoiding damage. Following the Factory Acceptance Test (FAT), each hoist and trolley assembly was treated with corrosion inhibitor and encased in UV-resistant plastic. They were packed in special hardwood containers with internal bracing. Control panels were enclosed in plywood and secured with shock-absorbing foam. Every fastener, spare part, and accessory was packed and labeled. English-language operation manuals, wiring diagrams, and maintenance checklists were printed and stowed in weatherproof document pouches on the crates.
4. Installation Support
Upon arrival at the plant, Yuantai first used a laser level to calibrate the track beams. Column bases were grouted and bolted, followed by the crane-lifting of bridge girders and adjusting wheel spacings. Hoists were mounted, ensuring proper clearance and settings. All bolts were torqued according to structural drawings, and wiring was routed along supports. This process, typically taking two weeks, was completed in ten days due to efficient planning.
5. On-Site Testing
Following installation, we performed on-site testing by powering the control panels and conducting no-load checks on all functions. Full-load tests used certified weights at 100% and 125% of rated capacity, measuring acceleration and comparing results to Factory Acceptance Test (FAT) data. We assessed safety features, making immediate adjustments for any issues. A final report documented test results and corrective actions.
6. Final Hand-Over
At project close-out, Yuantai provided a handover package that included as-built drawings of runway beam layouts and cable routes, inspection reports from Factory Acceptance Testing (FAT) and on-site tests, calibration certificates for load cells and sensors, and electrical wiring diagrams. A spare parts list for critical items like brake linings and control relays was also included, along with a maintenance schedule detailing lubrication points, brake and gearbox checks, and non-destructive testing recommendations. A dedicated support line and online portal were established for technical assistance and service requests.
Advantages of Yuantai's EOT Crane Solutions
1. Adaptability to Harsh Steel Plant Environments
Yuantai's EOT overhead cranes are built with heavy-duty components. Motors, gearboxes, and hoists have sealed housings. This protects them from heat, dust, and oil mist. The cranes operate reliably in the extreme conditions of steel manufacturing.
2. High Lifting Precision and Safety
Dual-speed hoists allow fast lifting of empty hooks. They switch to slow speeds when lowering or positioning heavy loads. This precise control prevents steel splashes and reduces the risk of accidents. Overload limiters stop lifts above rated capacity. Emergency stops engage mechanical brakes instantly.
3. Cost-Effective Modular Design
Double girder runway beams provide high headroom. This allows large loads like ladles and billet bundles. The modular hoist and trolley assemblies simplify on-site installation. Yuantai provided design drawings for client-fabricated girders. This shared fabrication model saved transport costs and customs duties.
4. Versatility for Multiple Applications
Beyond steel plant use, these EOT overhead cranes suit other heavy industries:
- Power Generation Plants: For lifting turbines, generators, and stator coils during maintenance outages.
- Oil & Gas Refineries: For moving heavy pipes, reactors, and heat exchangers in processing units.
- Shipyards: For handling ship blocks, engines, and hull modules during assembly.
- Cement and Mining Operations: For loading bulk materials and moving heavy mine equipment.
- Automotive Manufacturing: For lifting press frames, stamping dies, and large engine blocks on assembly lines.
Yuantai EOT Cranes for Steel Mills
Conclusion
This case study demonstrates how Yuantai's EOT cranes for Pakistan steel plant delivered a complete material handling solution. By understanding the steel production industry and the client's lifting challenges, Yuantai designed robust double girder overhead cranes with specialized hoists. Dual-speed, dual-control, and advanced safety features improved efficiency and reduced downtime. The cranes adapted to harsh workshop conditions and continuous heavy-duty cycles. Beyond this steel plant, similar EOT crane systems serve power generation, oil & gas, shipbuilding, mining, and automotive sectors. Yuantai continues to provide tailored overhead crane and material handling solutions that meet diverse industrial needs.
Contact Yuantai for Customized Crane Solutions
For professional advice on EOT overhead cranes, gantry cranes, or electric hoists for heavy industries, visit our overhead crane page or contact us for a free consultation.
