Heavy Duty Explosion-Proof 40-Ton Overhead Crane Kits to Pakistan

40 ton crane kit case study details how a customized 40-ton explosion-proof crane kit was delivered to Pakistan, ensuring safety in hazardous environments.

This case study focuses on a recent project where we provided a 40-ton explosion-proof overhead crane kit for a client in Pakistan. The client operates in a hazardous environment, which is why explosion-proof equipment was essential for ensuring safety and compliance with industry standards.

The crane kit we supplied was customized to meet the specific needs of the client’s operations. Importantly, this kit did not include the main girder, as the client planned to fabricate it locally. Our role was to provide all the other critical crane components, including the hoist trolley, electrical control cabinet, end carriages, and safety devices.

Why Explosion-Proof Equipment Was Necessary

The client’s facility is in a high-risk zone, which means there are flammable or explosive materials present. For safety, it was critical that all equipment used in the facility had explosion-proof certifications. This ensured the equipment would not trigger sparks or cause any accidents, even in the most dangerous conditions.

Scope of the Project

The project included:

• 40-ton crane kit for heavy lifting.
• Explosion-proof design for safe operation in hazardous areas.
• No main girder included (client to fabricate locally).
• Key crane components such as the electric hoist trolley, electrical control cabinets, and safety devices.

This customized solution provided the client with all the necessary parts to complete their crane setup, without the need to import the main girder, which could save costs and reduce shipping complexities.

Client Background

The client operates in the petrochemical industry in Pakistan, a sector that often deals with highly flammable materials and hazardous chemicals. This makes it crucial to have equipment that complies with strict safety standards. Their facility is located in a high-risk zone, which is why they need explosion-proof cranes to ensure safe and efficient operations.

The client initially reached out to us because they wanted a cost-effective and flexible solution for their lifting needs. After reviewing the options, they decided on a crane kit instead of a full crane system. The reason? They already have the capability to fabricate the main girder locally, which would save time and shipping costs. Our crane kit provided them with all the necessary parts, including the hoist, control systems, and safety features, while allowing them to manage the local fabrication of the girder.

By opting for the crane kit, they were able to cut down on installation costs and avoid the need for extensive international shipping.

Project Requirements

The client provided us with a clear set of technical specifications for the crane kit, which we carefully matched to their needs. Here are the key requirements:

• Lifting Capacity: The crane needed to handle up to 40 tons of load. This is a heavy-duty capacity, essential for lifting large and bulky materials within the facility.
• Span Sizes: The client required two sets of cranes, one with a 14-meter span and another with a 7.5-meter span. These dimensions were crucial for their workspace layout and lifting needs.
• Lifting Height: Both sets of cranes needed to have a lifting height of 10.5 meters, providing enough clearance for the operations in the facility.
• Explosion-Proof Standards: Given the hazardous environment, all equipment had to meet strict explosion-proof standards, ensuring that no sparks or heat from the crane could ignite flammable gases or chemicals.
• Power Supply: The cranes were designed to run on a 400V, 50Hz, 3-phase power supply, which is common in industrial settings and meets the local electrical grid specifications.
• Delivery and Payment Terms: We agreed on CFR shipping (Cost and Freight) to Pakistan, with 90% payment via Letter of Credit and the remaining 10% after the crane kit’s arrival and inspection.

These technical specifications ensured that the crane kit would meet the client’s operational needs while maintaining safety and compliance with local regulations.

Customized Crane Kit Solution

For this project, we provided a tailored crane kit that met all of the client’s technical and safety requirements. Since the client was handling heavy materials in a hazardous environment, the equipment needed to be not only robust but also explosion-proof to avoid any risk of sparks or ignition.

Here’s a breakdown of the components included in the kit:

• Explosion-Proof Electric Hoist Trolley: The hoist trolley is designed for heavy-duty lifting, rated for 40 tons. It’s equipped with explosion-proof motors and electrical systems to ensure safety in environments with flammable or explosive gases.
• Trolley Frame: The frame is built to support the hoist and distribute the weight evenly. It’s designed for smooth operation across the crane's span, ensuring that the load can be lifted and moved safely.
• End Carriages: These include the motor, wheels, and supporting structure. The end carriages are essential for the crane's long-travel movement and come equipped with explosion-proof motors to safely move the crane along the runway.
• Explosion-Proof Electrical Control Cabinets: These cabinets house the electrical controls for the crane, ensuring safe and reliable operation. They are designed to meet the explosion-proof standards needed for hazardous areas. The control system includes relays, circuit breakers, and the necessary wiring to keep the crane running smoothly.
• Hook Assembly: The hook assembly is designed to handle the 40-ton load, equipped with a safety latch and a heavy-duty hook that ensures secure lifting of materials.

Safety Devices: Safety is a top priority in hazardous environments. The crane kit includes several safety features:

• Limit Switches to prevent over-traveling.
• Overload Protection to ensure the crane doesn’t exceed its rated capacity.
• Emergency Stop System for quick halting of the crane in case of an emergency.

One key point to note is that the main girder is not included in the kit. The client has the capability to fabricate the main girder locally, allowing them to save on shipping costs and streamline the installation process.

  40 ton overhead crane kit - electric hoist and electrical control cabinet 


40 ton overhead crane kit - explosion proof hook 
40 ton overhead crane kit -  hoist trolley frame 

40 ton overhead crane kit - end carriage 

40 ton overhead crane kit  packed for delivery 

40 ton overhead crane kit - end carriages and other parts packed for delivery 
40 ton overhead crane kit  parts and components 

Key Challenges and Solutions

During the project, we faced several challenges, but each one was tackled with practical solutions to ensure the client received exactly what they needed.

• Meeting Explosion-Proof Compliance Standards One of the biggest challenges was ensuring that all components met the explosion-proof standards required for the hazardous environment. The client’s facility deals with flammable chemicals and gases, so it was essential to meet these strict safety regulations.
• Solution: We sourced all components from trusted manufacturers that meet IECEx and ATEX certifications. The explosion-proof electric hoist trolley, control cabinets, and all electrical systems were designed to function safely in hazardous areas.
• Aligning Electrical and Cable Requirements with Local Infrastructure The client’s local power supply was 400V, 50Hz, 3-phase, which is standard in Pakistan, but it required us to ensure compatibility between the crane's electrical components and the local grid.
• Solution: Our engineering team worked closely with the client to match the crane’s electrical system with the local infrastructure. This included ensuring that the wiring and electrical control systems were compatible with Pakistan’s power supply and complied with local safety standards.
• Smooth Communication for Customization Since the client was fabricating the main girder locally, it was important that we communicated effectively to ensure the crane kit’s components would integrate smoothly with their structure.
• Solution: We provided detailed drawings and technical specifications to the client’s fabrication team. Our team also stayed in constant contact with the client to provide guidance during the fabrication of the girder, ensuring the parts we delivered fit perfectly with the locally fabricated components.

These challenges were all addressed with a combination of expert engineering and strong communication. In the end, the customized crane kit met the client’s needs perfectly and was ready for installation in their hazardous environment. Let me know if you'd like to expand on any part of this.

Shipping and Delivery

Once the crane kit components were finalized and thoroughly inspected for quality, the shipping process began. The crane kits were carefully packed to ensure safety during transit and to prevent any damage.

• Packing and Container Allocation Each component was individually packed using high-quality, durable packaging materials. The parts were organized into several containers, with the largest components like the electric hoist trolley, end carriages, and electrical control cabinets properly secured in place to avoid any shifting or damage during transport.
• Container Loading We allocated the crane components across multiple containers, carefully organizing them to optimize space and ensure proper weight distribution. This process helped minimize potential risks during the journey. Detailed inventory lists were provided to the client, ensuring they had a clear understanding of what was inside each container.
• CFR Shipping Terms The crane kit was shipped under CFR (Cost and Freight) terms, meaning that the cost of the shipping and freight was covered on our side, but the client was responsible for import duties, taxes, and unloading fees once the shipment reached Pakistan’s port.
• Delivery Timeline The entire shipping process took approximately 6 to 8 weeks from the time the order was finalized to the kit’s arrival at the client’s facility. The client was regularly updated with tracking information, ensuring they were informed about the shipment’s progress.

Quality Inspection Before the crane kits were shipped, a rigorous quality inspection was performed. Our team conducted several checks to ensure that each component met the required safety and performance standards. The inspection included:

• Visual checks to ensure parts were free from damage.
• Functionality tests for motors, electrical components, and safety devices.
• Explosive-proof certifications for all relevant components.

The final inspection was conducted with the client’s specifications in mind, ensuring that all pieces met their operational needs.

Client Feedback and Results

Upon receiving the crane kits, the client provided positive feedback regarding the entire process, from delivery to installation and performance. Here’s a summary of their feedback:

• Product Quality The client expressed satisfaction with the overall quality of the crane kit components. The explosion-proof electric hoist trolley, end carriages, and electrical control systems performed as expected and met all safety standards. The client was especially impressed with the durability and robust design of the equipment, which was vital for their hazardous environment.
• Compatibility with Locally Made Girders Since the main girder was fabricated locally by the client, there were concerns about how well the crane kit components would fit with the locally made structure. Fortunately, the crane kit was perfectly compatible, and the components integrated smoothly with the locally fabricated girder. The precise specifications and clear instructions we provided helped ensure a seamless fit.
• Ease of Installation The client was pleased with the ease of installation. The crane kit arrived with detailed installation manuals and technical drawings, which made the assembly process straightforward for their team. They were able to complete the installation without any major issues, saving both time and labor costs.
• Overall Satisfaction The client was highly satisfied with the performance of the crane after installation. The crane operated smoothly, lifting heavy loads safely, and the explosion-proof features provided peace of mind when working in such a hazardous environment. The safety features, including limit switches and overload protection, were particularly appreciated, as they helped prevent accidents and ensured operational safety.

In conclusion, the crane kit met all of the client’s expectations, and they were pleased with the reliable performance, safety features, and cost-effectiveness of the solution. The positive feedback confirmed that our customized crane kit was the right choice for their hazardous environment, and the client is looking forward to using our cranes in their future projects.

Why the Client Chose Yuantai Crane

The client’s decision to choose Yuantai Crane as their crane supplier was influenced by several key factors. Here’s why they trusted us with their project:

Experience in Providing Explosion-Proof Crane Systems

Yuantai Crane has a proven track record in delivering explosion-proof crane systems. Our expertise in designing and manufacturing cranes for hazardous environments was a major selling point for the client. They knew that we could meet the strict safety standards required for their operation.

• Proven expertise in explosion-proof systems.
• Deep understanding of hazardous environments and safety needs.

Flexibility in Supplying Crane Kits Without Main Girders

The client appreciated the flexibility of our crane kits, which are offered without the main girder. This allowed them to fabricate the girder locally, saving on shipping costs and giving them more control over the installation process. This customization suited their needs perfectly.

• Crane kits supplied without main girders.
• Cost-effective solution with local fabrication.

International Certifications (CE, ISO)

Our international certifications, such as CE and ISO, gave the client confidence in the quality and safety of the crane kit. These certifications ensure that our products meet global safety standards and reliable performance, making us a trusted partner for their project.

• CE and ISO certifications.
• Guaranteed compliance with international safety standards.

Responsive Technical Support

Another reason the client chose us was our responsive technical support. Throughout the project, our team was readily available to answer questions, provide guidance, and assist with any issues that arose. This level of support helped build trust and ensured a smooth experience from start to finish.

• 24/7 technical support throughout the project.
• Quick and efficient assistance for installation and customization.

Conclusion

This project was a success from start to finish. The 40-ton explosion-proof crane kit met the client's needs for safety, performance, and cost-efficiency. By working closely with the client, we were able to provide a customized solution that fit their unique requirements for a hazardous environment.

• On-time delivery and successful installation.
• Smooth integration with locally fabricated girders.
• High satisfaction with the crane’s performance and safety features.

Looking ahead, we’re excited to continue working with the client and exploring new opportunities for collaboration. If you’re operating in a hazardous environment and need a customized crane solution, don’t hesitate to reach out to Yuantai Crane. We’re here to provide tailored crane solutions that meet your specific needs, backed by global certifications and a team that’s always ready to help.