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A bespoke overhead crane modernisation project at a water pumping station in Kent has improved the safety, efficiency and reliability of an important piece of lifting equipment.
The crane plays a key role at the site, allowing critical pumps to be lifted out of position for maintenance. As part of wider refurbishment works, Street Cranexpress was appointed to upgrade the existing manually operated crane while retaining much of the original structure.
Overcoming the Limitations of Manual Operation
The existing crane dated back to the 1960s and was operated manually. This placed additional physical strain on operators, while the relatively slow operating speed meant removing and replacing pumps could be a lengthy process.
Modernising equipment of this age also presented several engineering challenges. There were no original engineering drawings available, so the project team had to develop the new system from the ground up while working around the retained crane beams, end carriages and wheels.
One of the more complex aspects involved matching new long travel drive pinions to the crane's existing wheel spur gears.
The location of the pumping station added another challenge. Poor access to the remote site made the delivery and offloading of equipment, together with the provision of test weights for commissioning, more difficult and required careful planning throughout the project.
A Bespoke Electric Crane Upgrade
The redundant manual components, including the original hoist and long travel drive gear, were removed before a new electric lifting and control system was installed.
The upgraded crane includes a new 5-tonne electric chain hoist, long travel motors, C-Track festoon system, radio remote control, long travel limit switches and an enclosed DSL system.
A new main control panel was designed and manufactured in Sheffield and incorporates a variable speed drive to provide more precise control of the crane. Schneider Electric components were used throughout the control system, including variable speed drive and contactor technology.
From Design Through to Load Testing
The project progressed from an initial site scoping visit through detailed design, approval of general arrangement drawings and procurement before installation, commissioning and load testing.
The design and procurement phase took approximately 12 weeks, followed by seven days of installation and commissioning on site.
The completed modernisation has replaced the labour-intensive manual operation with an electric system, reducing physical strain on operators while providing more precise positioning and faster crane movements.
The increased operating speed also helps reduce the time required to remove and replace pumps during essential maintenance work.
By retaining the existing structure while replacing and modernising the lifting and control equipment, Street Cranexpress has extended the useful life of the crane and delivered a system better suited to the requirements of a critical water infrastructure site.
For more information on Modernising a 1960s Overhead Crane at a Kent Water Pumping Station talk to Street Cranexpress Ltd