Navigation
Related

Special marine overhead crane with a lifting capacity of 3 tonnes

Izhora Hydrosystems LLC presents a special-purpose marine overhead crane with a lifting capacity of 3 t, designed for lifting, lowering, and longitudinal and transverse handling of cargo within a ship’s hold. The crane is intended for handling cylindrical loads with diameters ranging from 123 to 533 mm and lengths of up to 8 m. During cargo handling operations, the crane ensures:

  • rigid fixation of the load on the suspension system;
  • absence of load rotation and sway in both transverse and longitudinal directions.

The marine overhead crane was developed for installation on a naval training torpedo recovery boat of the Russian Navy and is intended for recovery of practice (inert) torpedoes from the water after training exercises. The crane design incorporates non-standard engineering solutions aimed at reducing overall mass and dimensional characteristics.

The lead project of the special-purpose marine overhead crane, developed under contract for the Navy, complies with the following regulatory documents:

  • Technical Specification;
  • Rules for the Classification and Construction of Sea-Going Ships of the Russian Maritime Register of Shipping (RS);
  • Rules for Lifting Appliances of Sea-Going Ships (RS);
  • Rules for the Design and Safe Operation of Lifting Appliances for Naval Support Equipment (PGU SO VMF-83);
  • Order of the Minister of Defence of the Russian Federation No. 792 dated 21 December 2017.

Izhora Hydrosystems LLC is ready to adapt the marine overhead crane design for naval and civilian applications, taking into account the structural and operational characteristics of the customer’s vessel.
The crane can be customized for handling cargo with any specified parameters in ship holds of various types, as well as for operation at stationary onshore facilities.

Advantages of the Special-Purpose Marine Overhead Crane

The special-purpose marine overhead crane manufactured by Izhora Hydrosystems LLC offers the following advantages:

  • Pricing independent of foreign currency exchange rates, ensuring cost stability throughout the project lifecycle.
  • Contractually defined and reliably maintained delivery schedules, justified by the scope of work and ensured by the absence of dependence on foreign manufacturers.
  • High reliability and maintainability, as the crane is manufactured exclusively from Russian materials and components, allowing installation on naval vessels and other facilities of the Ministry of Defence of the Russian Federation.
  • Versatility: when equipped with appropriate lifting attachments, the crane can handle a wide range of cargo types.
  • Compact design and reduced requirements for crane runways, as no moving drive units are installed on the bridge or trolley, resulting in lower loads on the vessel’s structural elements.
  • Rated service life before factory overhaul of 10,000 operating hours or 13 years.
  • Custom engineering capability, allowing development of a unique marine overhead crane adapted to restricted installation spaces and complex cargo handling tasks.

Depending on the purpose, class, and operating area of the vessel, Izhora Hydrosystems LLC adapts the special-purpose overhead crane design to comply with the requirements of the Russian Maritime Register of Shipping, the Russian River Register, the Ministry of Defence of the Russian Federation, and other relevant regulatory and supervisory authorities.

Optional Equipment and Configurations

In the standard configuration, the crane is equipped with a twin-drum winch, with wire rope tension maintained by a spring-loaded tensioning unit. For improved rope reeving and more accurate load positioning, the crane may be equipped with two independently driven winches, each operating with a separate wire rope on its own drum. This configuration eliminates the need for symmetrical winding of identical wire ropes and allows independent tension adjustment.

Wire rope tensioning by the twin-drum winch of the overhead crane

For technical consultations or to place an order for the marine overhead crane, please contact:
Phone: +7 (812) 339-61-68
E-mail: contact@i-hydro.ru

Development History and Design Features

Izhora Hydrosystems LLC was approached by a shipyard that was unable to identify a Russian manufacturer capable of delivering the full project cycle for a special-purpose marine overhead crane, including engineering design, approval by supervisory authorities, manufacturing, and commissioning. The task was further complicated by severe dimensional constraints, particularly strict limitations on the overall crane height, which fully excluded the use of standard serial overhead cranes produced by conventional crane manufacturers.

In response, Izhora Hydrosystems LLC designed and manufactured a custom special-purpose marine overhead crane, implementing a non-standard technical solution that enabled installation of the equipment inside the hold of a torpedo recovery boat. In this design, the bridge and trolley are driven by tensioned wire ropes from a twin-drum winch, with no moving drive units installed on the bridge or trolley. As a result:

  • requirements for crane runways were reduced;
  • the overall structure was made highly compact;
  • crane height above the runway was minimized;
  • the moving mass of the crane system was significantly reduced.

The crane was designed and manufactured in full compliance with the customer’s technical and operational requirements.

Operating Conditions and Operational Features

The marine overhead crane is designed for reliable operation at ambient temperatures from –32 °C to +30 °C and under sea conditions up to Sea State 3. The crane bridge has two primary positions: working and stowed.

Special marine overhead crane in stowed position

When the vessel is underway and the crane is in the stowed position, the following conditions apply:

  • The piston rods of the fixation hydraulic cylinders are extended.
  • The load trolley is secured by four wire-rope lashings to deck pad eyes.
  • The piston rod of the load hoisting/lowering hydraulic cylinder is locked to prevent unintended lowering.
  • No load is suspended.
  • The wire ropes are correctly reeved, properly spooled on the drums, and kept under tension.
  • Doors of the electrical cabinet and hydraulic power units are closed.
  • The control pendant is stored in its designated stowage location.
  • Power supply is switched off.

In the working position, winches are used to move the crane bridge and load trolley along the ship’s hold, while the load trolley hydraulic cylinder performs lifting and lowering of the load.

Crane operation includes the following procedures:

  1. Preparation for operation, including inspection for completeness and absence of visible damage.
  2. Transition of the crane from the stowed position to the working position: removal of trolley securing lashings, piston rod locks, and pivot locking rods.
  3. Power supply connection to the control cabinet, activation of the hydraulic power units, and hydraulic oil pre-heating if required.
  4. Starting the hydraulic power units.
  5. Removal of the control pendant from the trolley housing and switching the crane to operational mode.
  6. Functional check of all operating motions.
  7. Inspection for absence of hydraulic fluid leakage.
  8. Execution of lifting and cargo handling operations.

In abnormal or emergency situations, crane operation is stopped and blocked by pressing any EMERGENCY STOP push button located on the control pendant or hydraulic power units.

Upon completion of cargo handling operations, a visual inspection of the equipment is carried out to verify the absence of mechanical damage and confirm proper technical condition.
The crane is then returned to the stowed position, the hydraulic power units are shut down, and the power supply is disconnected.

Technical Specifications

  • Safe Working Load (SWL) at Sea State 3 – 3000 kg.
  • Lifting height – 1.3 m. 
  • Hoisting / lowering speed – 0-2.0 m/min. 
  • Trolley travel – 4.54 m. 
  • Trolley speed – 0-3.0 m/min. 
  • Crane bridge travel – 8.5 m. 
  • Crane bridge travel speed – 0-6.0 m/min. 
  • Weight – max. 3400 kg. 
  • Hydraulic system operating pressure – max. 25 MPa.
  • Manual pump handle force – max. 16 kgf. 
  • Working fluid – AUP hydraulic oil, TU 38.1011258-89.
  • Guide rail (channel rail) length – 11.4 m.
  • Overall dimensions – 11442 х 6400 х 2269 mm. 
  • Installed motor power – 13.26 kW.
  • Power supply – 3-phase / 380 V / 50 Hz. 
  • Operating temperature range from –32 °C to +30 °C. 

General Arrangements and Design

  1. crane rails (runways);
  2. bridge;
  3. load trolley;
  4. hoisting mechanism;
  5. bridge locking mechanism;
  6. bridge travel drive;
  7. trolley travel drive;
  8. hydraulic equipment installation;
  9. electrical equipment installation;
  10. portable control pendant;
  11. control cabinet;
  12. bridge hydraulic power unit (HPU);
  13. trolley hydraulic power unit (HPU).

The crane bridge is a welded steel structure that moves on support rollers along crane rails welded inside the hold to the vessel’s side and deck structural members. The rails are manufactured from No. 20 steel channel sections, reinforced on the underside with plate-steel stiffening ribs. The welded load trolley, equipped with its own travel drive and dedicated hydraulic power unit, travels along the bridge on support rollers.

Hoisting mechanism with drive and hydraulic equipment

The load hoisting and lowering mechanism, installed on the load trolley, is a two-stage telescopic system with a single centrally mounted hydraulic cylinder.
To allow load engagement at an angle, a hinged fork with a lifting yoke compliant with OST V5.2423-83 is mounted at the end of the hydraulic cylinder rod.

To reduce load sway, the crane is equipped with a spreader beam incorporating pivoting guide rods fitted with calibrated guide rollers and limiting clamps. Additional removable gauge limiters may be installed on the pivoting rods to facilitate handling and positioning of loads shorter than 3 meters.

Operating principle: during hoisting or lowering, the rollers roll along the surface of the load without restricting vertical movement, while the limiting clamps prevent rotation of the load about the hydraulic cylinder rod axis. When the load reaches the uppermost position, the pivoting guide rods are locked by the load fork via a roller stop. This prevents load sway during subsequent transverse and longitudinal movement within the hold for placement in the designated stowage location.

Two independent wire-rope winches, powered by two separate hydraulic power units (HPUs), are used for traveling the crane bridge and the load trolley. Travel is limited by end-position sensors and fixed mechanical end stops. Each winch comprises a grooved drum for wire rope spooling, a gearbox, a brake, and a hydraulic motor.

Second drum of the twin-drum winch for bridge travel of the special overhead crane

Fixation of the crane bridge in the stowed position is provided by brackets welded to the crane runways and fitted with hydraulic cylinders. The cylinders extend locking rods into travel limit stops welded to the crane bridge, ensuring secure locking during vessel transit.

Control cabinet of the special marine overhead crane

The steel control cabinet houses the electrical control equipment, hydraulic power unit control devices, and operating status indicators for both the hydraulic power units and the crane. The cabinet is equipped with interfaces for main power supply connection and for connecting the portable control pendant cable.

The cable-connected portable control pendant is a handheld unit equipped with crane control and status indication devices. For operator convenience, it is fitted with a shoulder strap. In the stowed position, the wearable control pendant remains connected to the load trolley and is stored on the protective cover of the hoisting hydraulic cylinder.

Operational Safety of the Marine Overhead Crane

The marine overhead crane and all equipment included in its configuration comply with generally accepted standards in force at the time of design and manufacture and are recognized as safe for operation.

The equipment shall be used only under the specified and safe operating conditions. During operation, due caution shall be exercised, with continuous visual monitoring of crane operation, the position of moving parts, and the reeving and spooling of wire ropes.

To ensure safe operation of the crane, the following requirements shall be observed:

  • Strict compliance with the Operation and Maintenance Manual of the crane, as well as the documentation for all equipment operating in conjunction with the crane.
  • Compliance with applicable fire safety regulations.
  • Preservation of factory-set safety device parameters; all protective systems shall remain enabled and shall not be bypassed or blocked.
  • Operation strictly within the permissible operating limits of the equipment.
  • Installation, dismantling, maintenance, and repair work shall be performed only with all power supply feeders de-energized and secured against inadvertent re-energization.
  • In the event of a malfunction or failure, operation shall be stopped immediately until the cause has been identified and eliminated.

During functional testing of the marine overhead crane, only personnel directly involved in servicing the equipment are permitted to be present within the working area. All testing shall be carried out under the supervision of a designated responsible person.

The electrical equipment and control system of the marine overhead crane provide the following primary interlocks and protective functions during operation:

  • Overload protection: limitation of lifted load exceeding 110% of the rated load capacity of each hoist.
  • Overcurrent protection: tripping in the event of current exceeding preset limits.
  • Earth leakage current protection: tripping in the event of leakage current exceeding established limits.
  • Control system fault monitoring: interlock activation upon detection of control system failure.
  • Emergency stop: manual activation via emergency stop push buttons.
Bridge hydraulic power unit of the marine overhead crane

To ensure operational reliability and fault tolerance, the marine overhead crane is equipped with:

  • Power supply from two independent feeders with automatic changeover.
  • Redundant pump drives within the hydraulic power units.
  • Capability for crane operation in the event of complete loss of electrical power using manual pumps with manual switching of actuators.

In emergency operation mode, hydraulic pressure required for crane operation is generated by manual pumps installed on both the trolley and bridge hydraulic power units. The pumps are positioned to allow convenient and safe operation at any location along the crane travel path within the cargo hold.

Documentation and Warranty

To maintain the marine overhead crane in proper technical condition, ensure continuous operational readiness, and guarantee correct and safe operation, the requirements of the Operation and Maintenance Manual developed by Izhora Hydrosystems LLC shall be strictly observed. Failure by operating personnel to comply with the rules and requirements of the Operation and Maintenance Manual shall invalidate the right to submit warranty claims.

The obligations and warranty responsibilities of the manufacturer, Izhora Hydrosystems LLC, are defined in the equipment supply contract. The scope of warranty obligations stipulated in the contract shall not be expanded or restricted based on information contained in the Operation and Maintenance Manual for a specific unit.

Hydraulic equipment installation and trolley hydraulic power unit of the special marine overhead crane

The standard scope of supply includes:

  • Marine overhead crane, assembled — 1 unit;
  • Spare Parts and Tools (SPT) — 1 set;
  • Documentation in accordance with the Product Passport — 1 set.

The scope of supply for optional equipment may differ from the configurations and illustrations presented on the website, as the equipment is manufactured in various versions, configured according to customer requirements, or modified in line with ongoing engineering development.

The crane is supplied in disassembled and packaged condition by any mode of transport that ensures compliance with Storage Condition “8” in accordance with GOST 15150-69. Prior to transportation, crane assemblies are preserved and packaged by the manufacturer, with the exception of oversized structural elements. Preserved equipment assemblies and the SPT kit are secured in robust packaging that prevents mechanical damage and protects against environmental exposure during transportation and storage.

Each package contains a packing list or shipping note, signed by a Quality Control (QC) representative after verification of completeness, securing reliability, and preservation quality.

All third-party components supplied by other manufacturers and incorporated into the marine overhead crane undergo incoming inspection at the production facilities of Izhora Hydrosystems LLC.
To confirm compliance with applicable national standards, suppliers provide the relevant certificates of conformity.

The operational documentation of third-party components forms an integral part of the Operation and Maintenance Manual of the marine overhead crane. All instructions related to occupational safety, commissioning, installation, operation, maintenance, dismantling, and disposal of auxiliary equipment shall be observed in full and without exception.

The manufacturer, Izhora Hydrosystems LLC, guarantees a service life of the marine overhead crane of 5 years from the date of vessel commissioning, provided that the equipment is operated in accordance with the requirements of the Operation and Maintenance Manual.

For technical consultations or to place an order for the marine overhead crane, please contact:
Phone: +7 (812) 339-61-68
E-mail: contact@i-hydro.ru