Evers supplies 280 tonne lifting beam to MAN Turbo AG

The mechanical engineering firm MAN Turbo AG with head office in Oberhausen has the worldwide widest range of products for turbo machines. MAN Turbo has been offering customised solutions from a single source for over 100 years; from the individual machine through to the turnkey set of machines.

The mechanical engineering firm MAN Turbo AG with head office in Oberhausen has the worldwide widest range of products for turbo machines. The offer includes individual machines and complete machine lines, from new-build plant to after sales service for compressors and turbines. MAN Turbo has been offering customised solutions from a single source for over 100 years; from the individual machine through to the turnkey set of machines.

As a complete provider for lifting, securing, conveying and packing, Evers GmbH in Oberhausen (www.eversgmbh.de) has for many years been supplying Man Turbo with all kinds of different load handling equipment. Innovative and creative advice, sustained reliability, top problem-solving expertise even for individual requirements and the advantages of short travel distances are the basis of the longstanding cooperation between the two Oberhausener companies.

Customer's requirements
The trigger for the investment in a 280 tonne lifting beam was a large order for the supply of eight complex units, equipped with industrial turbines and compressors. The machines weight up to 250 tonnes and have dimensions of around 13 metres long, 7 metres wide and 5 metres high.

Before delivery to the customer, these machines are to be tested on MAN Turbo AG's test rig in Oberhausen at a height of almost seven and eleven metres respectively under real conditions. The tops of the machines reach up to 15 metres high.

Solving the in-house transport of the machine parts during the assembly work was a complex task. To date, the machines were lifted by their four anchor bollards with the help of a factory crane and up to three mobile cranes. This cost-intensive procedure also requires enormous space and time. In addition, in the meantime MAN Turbo has registered an increase in orders with these weights and dimensions. Mobile cranes with a rated load of 500 tonnes are required in order to be able to lift the weights required for the test with the necessary working radius. However, the standing area required for these is urgently needed for other assemblies. In addition, erecting and dismantling the cranes takes up to one day each.

Project objective
MAN Turbo, Evers and their cooperation partner Axzion-GKS from Langenfeld, which is specialised in "intelligent load handling equipment", which is developed in close collaboration with the users, define a common project objective: Deployment of the mobile cranes will be eliminated. In-addition, in-house transport of the machines will be accelerated. Costs, time and hall space for other assemblies will be saved and in this way will contribute to increasing the economic viability of the overall project.

Project planning
The task is extensive. The companies involved know that the project objective will be difficult to achieve. Christoph Bergforth, managing director of Evers and Raimund Rötzel, managing director of Axion-GKS, advise MAN Turbo to replace the mobile cranes with a specially produced H load lifting beam with 2 crane anchorage.

A lifting beam is a mechanical carrying device used for stabilisation, attachment or connection. They are frequently used as load handling equipment for attaching loads, i.e. "to get them on the crane" and always when the objects are to be hung over a certain width. Depending on the intended use, a differentiation is made between a planar version (e.g. beam or spreader lifting beams) or spatial types (e.g. H or frame lifting beams). Both versions are individually built according to their intended use with numerous special versions, e.g. frame lifting beam for containers, telescopic recovery lifting beams, hydraulic settlement lifting beams for bridge members, back-up roll lifting beams, tubular lifting beams for heavy duty roundslings or modular lifting beams with optional longitudinal or transverse lifting beams.

Realisation
The 57 tonne lifting beam design derived from the customer's requirements and the project objective means intensive cooperation between Evers and Akzion-GKS for the product development and the associated engineering tasks, the logistical requirements and resource allocation, both with respect to personnel and materials management.

The main problems of this sophisticated project are as follows:

1. The geometries of the machines differ. The load centre of gravity is never exactly in the middle of the four attachment points. This is very easy to solve when the mobile cranes are used, in that the cranes pull with different forces and therefore prevent turning and tipping of the machines.

When a lifting beam is used there is a risk of tipping up under certain circumstances. This is also the case here, as the attachment points on the load are located below the machine's centre of gravity. In an extreme case the load can fall. The new lifting beam must be especially equipped for this requirement.

Lifting beams are normally preset and anchored onto the load, i.e. hung onto the crane. If it is found that the load does not hang straight, the centre of gravity has been incorrectly set, it is necessary to detach and attach the load again. To this end, the lifting beam is detached, placed on the ground and reset. As the load's centre of gravity is only approximately known, this is a trial and error process and is repeated until the load hangs straight. One trial can last two to four hours. Sometimes trials last days until the load hangs straight. The new lifting beam is deigned so that it is possible to adjust with the load attached, to enable efficient working.

2. The assembly halls of MAN Turbo, despite being raised, are still very low. The machines will be assembled at a height. The space between the top of the machine and the bottom of the lifting beam is only 15 cm.

Following extensive planning and engineering work by Evers and Akion-GKS, the following lifting beam was produced (extracts from the specifications): Axzion GKS load handling equipment with two cranes, rated capacity: approx. 300,000 kg, self-weight: approx. 55 tonnes. The lifting beam is designed for different transport tasks in two different MAN Turbo AG assembly halls in Oberhausen. The distance between the rigid crane anchorages is approx. 16 metres. Additional features: Longitudinal lifting beam with electrical drives for adjustment of the transverse lifting beams. Transverse lifting beams with electrical drives for adjustment of the attachment points. Individual adjustment of the longitudinal and transverse lifting beams is therefore possible; however, not under load. Load side: Two adjustable transverse lifting beams, 10,000 millimetres wide, which can be moved along the longitudinal lifting beam. Centre of gravity adjustment in the longitudinal direction by moving the transverse lifting beams on the longitudinal lifting beam in their hung state. Load distribution for the different crane working load limits of assembly hall 1 by means of asymmetrical adjustment of the transverse lifting beams on the longitudinal lifting beam. The load-side attachment points on the transverse lifting beams are suspended from crane trolleys with ball bearing supports. The trolleys can be steplessly adjusted by means of electric chain hoists. This does not require detaching the lifting beams. Centre of gravity adjustment in transverse direction is possible by means of the asymmetrical arrangement of the trolleys relative to the longitudinal lifting beam.

The lifting beams will be produced in the Langenfeld factory. Final assembly of the large dimensioned lifting beam parts will take place at MAN Turbo in Oberhausen. Serviceability of the lifting beams will be confirmed by successful final acceptance.

Notes on attachment below the load's centre of gravity with lifting beams

Please note and comply!

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Christoph Bergforth

Executive Sales, Director

tel. + 49 208 99475-41

Send e-mail