UK Nuclear Licensed Site – 125t Nuclear Product Facility Crane

Hoisting specification

• A 125t main hoist gives 18.6 metres of true vertical lift via 2 ropes and 12 falls from a twin-scrolled drum, which can be Castell key-locked to a slow hoisting speed of 100mm/min
• For the most delicate operations a SIL2-rated, key-locked slow speed of 0.025m/min applies to both long and cross travel, with a fast speed of up to 5m/min, via independent variable speed drives
• A 10t auxiliary hoist is provided for lighter lifting and servicing tasks

Rigorous development

• Given the crane’s large SWL, sensitive loads and strict nuclear safety requirements, SCX’s meticulous approach ensured a compliant, high safety, high integrity design
• This process included BIM-compliant 3D modelling of the crane for clash detection studies and finite element analysis (FEA) validation
• Substantiated EC&I systems were developed for safe, accurate and repeatable handling of nuclear material

Modular design meets bespoke engineering

• The crane is of a modular design, using industry-proven components, ensuring reliability and performance with minimum maintenance
• The 18-metre bridge span is reinforced to keep deflections within required tolerances, while material compatibility analysis ensures compliance with the client’s manufacturing environment
• All crane motions have an M5 duty rating, ensuring high reliability throughout its 40-year working life

Seismic integrity

• SCX undertook a comprehensive and independently-verified design assessment to ensure the system would not compromise the building’s integrity in a seismic event
• Long-travel side guidance rollers combine with flanged and unflanged wheels to minimise skew, while also allowing a degree of safe lateral motion during seismic vibrations
• Anti-uplift brackets are fitted on both long travel and cross travel, preventing the crane or crab from leaving their rails

Multi-layered safety

• An on-crane HMI panel provides a means to configure safety modes, facilitates supervisor login, and displays
  all alarms and fault conditions
• The design includes laser positioning, multi-layer over-raise protection, motion interlocks, mis-spooling  protection, limit switches and encoders
• Machine safety layers ensure that all crane operations are safe and in complete control

MotoSuiveur load arrest

• The innovative MotoSuiveur load arrest device is available exclusively through SCX Special Projects in the UK
• The device provides a mechanically independent load arrest solution, bringing uncontrolled loads to a safe and damped stop within 30° rotation of the drum, or a load drop of <25mm
• Arrested loads are recovered via the MotoSuiveur’s auxiliary drive – after activation and recovery, the system can be quickly reset and ready to continue operation

Clarity of control

• Operation is remote via a substantiated and 24-bit encrypted Cattron radio control, while the PLC-controlled drives and hoist are programmed with lifting profiles to automate complex handling procedures
• The hoist design accommodates load positioning and rotational tolerances, while eliminating potential issues of side-loading and mis-spooling
• Dual load cells and X-Y-Z hook position sensors send operational data to a bright, crane-mounted LED display

Clean room compliance

• Loose Article Control (LAC) compliance was assessed via a detailed 3D virtual reality inspection of SCX’s BIM-compliant model
• The number of fixings is minimised, nuts and bolts are individually locked and labelled, and the crane is painted with a special clean room finish
• Walkways, ladders and rails are made from stainless steel to minimise contamination, while openings on the structure are carefully planned and infilled to prevent dropped items

All under one roof

• A blend of industry-proven COTS lifting equipment with expert mechanical, electrical, controls and safety engineering design
• SCX took the project from initial concept designs, through engineering and calculations, to manufacturing and build, to installation and commissioning
• Comprehensive factory acceptance testing was  undertaken at our Sheffield assembly facility, followed by site acceptance testing during final commissioning