The annual Portal Crane Users Committee meeting was held at Chattenooga, Tennissee May 10 to 14, 1999. The meeting was called to order on Tuesday May 11, 1999 by John Peak. Tom Maron reviewed the TAPPI/CPPA anti-trust Policy. The meeting was then turned over to Ken Landry and all participants introduced themselves.

Ken Landry then gave a brief background of the Portal Crane Users Group Committee.

Ken Landry canvassed everyone for Round Table discussions. The following topics and a few comments made by the users:

Issues

Problem, Causes, Solutions

· Trolley rails rough, Poor alignment, Do wheel alignment

trolley wheels

Motor- drive imbalance, Check out electronics

Bad jointsRedo the splices

Uneven rail, Re-grind rail

Rough wheels from spalling, Change out wheels

Gantrex pads failing, Poor installation, Install properly

Squeezing out at couped, Install keeper or Install poly pad

Thermite welds failure, Improper application, Cut out and repair

Alternate joint methods?, Flashbutt

Bolted splice

Angle slice

Thermite

Quality of gantry wheels?, Determine the hardness and the quality specs by working with you parts supplier and check to see if you are in fact getting what you are asking for and paying for. You can run a harder wheel in southern climates then in areas that reach 55 below.

Wheel diameters, It is imperative that wheel diameters are closely matched

Motors AC vs. DC?, Both have their good points and their bad points. D.C. motors require more attention overall. The jury is still out on which is better for crane use.

Overspeed problems, Wheel spin can damage motors, by over speeding, Seattle crane seems to have a solution

Mechanical failure in drive line, Same as above, can result in motor over-speed

Rebuild issues, Poor rebuilds, Build relationship, Motors don’t operate after, with rebuild shop, rebuilds, Work with them

Some people send new motors to get the quality to rebuild shop to be checked you require out. Have motors speed rated, Set standard,

Reliance motor issues, Will work to send letter to reliance from several users stating reasons for dissatisfaction.

Poor cable keepers, leaves too small a margin for error, Check your sheaves for wear

Shockloading, solution, Operator training

Overloading, Poor load monitoring

Wire rope quality, Change supplier of cable and Try higher grade of cable

Overall recommendation better operator training for wire rope failures

Hoist drum wear,Ropes not in laggingOperator training

No cable lubrication, Lubricate cables

Plastic coated cables, Contaminants to damage cables and hoist drums!

The following issues were also discussed but did not go to the round table discussion groups:

Grapples

high profile verses low profile

Guide wheels both gantry and trolley

Bushings on support pins

Welds

Alignment systems what works?

Wheel wear

Storm and hoist brake issues
The relationship between the fixed leg, hinged leg and guide wheels

Bumpers and anti-collision systems
anti-collision systems
Round table discussions and reports were completed about 5:30 and the meeting was adjourned for the day.

Wednesday, May 12, 1999

John Peak called the meeting to order. Ken Landry gave the TAPPI/CPPA anti-trust rules. He reminded everyone that the price of any items cannot be discussed.

Ken Landry reminded everyone that any breach of these rules presentation would be stopped one presenter would not be allowed to continue.

Mr. Bressler and his company have 18 years experience in the field of Structural Analysis. He began by discussing why inspections are important. Detecting failure causes was just one of the damage, corrosion, metal fatigue, and improper loading stress.

Mr. Bressler stated that during inspections issues of safety, preventative maintenance , longevity, catastrophic failure, and avoiding downtime were addressed. When these issues are confronted through inspections before they become a problem, your company can increase profit and save dollars.

Any method of visual inspection is called Non-destructive Testing. Magnetic partical testing is a popular method of Non-destructive testing for surface flaws or flaws slightly below the surface. The Wet Process or the Dry Method can be used with the same results. If it is necessary to determine the depth of the flaw, Ultrasound testing can then be used. There are two types of Ultrasound testing; contact testing or immersion testing are both types of Ultrasound. All found defects should be marked with a permanent marker for later repair.

Mr. Bressler noted that the most effective way to examine pins is by using the Ultrasound Testing Method. Most pins are accessible from the ground, but some are as high as 150' in the air.

Any time that there is an accident on the crane, a Structural test should be performed. The damage found determines whether or not the equipment is repaired or replaced. If repair work is required, a complete inspection should ensue until all equipment is again operable.

Mr. Bressler will provide your company with documentation that will also be required by OSHA which includes pin inventory, pictures, defect summary, cord inventory, etc. If any damage or flaws are found, each part will be rated accepable, rejectable, or fracture critical. Fracture critical ratings can be cause for crane shutdown. It will not be allowed to function until the crane passes OSHA requirements.

Does paint interfere with ultrasonic testing?

What type of certification is required of someone to do these sorts of inspections?

Answer: There are different Classes to be accomplished and a Class 11 is required.

Who certifies them?

Answer: American Society of Non-destructive Testing.

End of presentation 10:15 A.M.

May 12/99

10:30 A.M.

SEW Eurodrives, Enclosed gear drives

Jim Walsh

Eurodrive Gear Motors are failsafe and can withstand 1000's of emergency stops. The brake has two coils to reduce heating issues. The accelerator coil causes rapid stops and the small holding coil reduces heat. If a coil goes bad in the brake, the rectifier needs to be changed at the same time as the coil. Doing this will give you a whole new brake.

Some parts have multiple numbers if a replacement is ever needed. Eurodrive provides charts to help determine exactly what parts you need. The only parts that you must purchase through Eurodive are the internal parts. Other parts do not have to be purchased directly from Eurodrive. They can be purchased from other suppliers example The bearings can be purchase by bearing number from your local dealer, these dealers are the same people that Eurodrive originally purchased from.

Eurodrive parts from Europe will include one plate, whereas parts from the U.S. will include two plates. Included on a part plate is a SO# that enables customers to inquire about a particular part from suppliers all over the U.S. The type of oil needed for a part is also included on the plate. In the U.S. two types of oil are used: Mobil 630 and SAC 629. Mobil 630 is a mineral oil that is changed only once a year.

The life of the gearing is a lifetime if there is no overloading, bearings are kept fresh , and the oil is changed as required. Eurodrive warranty is usually one year in service.

End of presentation 11:10

There was no questions.

May 12/99

11:10 A.M.

P&H Cranes, Morris Material Handling

Gary Otto

The Portal Crane Operators work environment has not changed much since 1960 until the 1990's. In the 1990's the cabs were evaluated for visability, access, seat, controls, environmental conditions and emergency escape routes. P&H Cranes discovered ways to improve these conditions and have helped to develop a cab that is more comfortable and user friendly.

Today’s Portal Crane is designed with all around vision for the operator. The access to the cab was improved with rear stairs and a side door. The cabs were also set back 24' , 33' , 41' . The cab interior now has shelves for microwave, radios, refigerators, etc. New seats have been constructed for comfort and lumbar support.

Mr. Otto provided reports describing the highlights of their study of Ergonomics in the work place for Portal Crane Operators. The highlights of their study included prevention, OSHA standards, risk factors, controls, and a brief summary.

Reducing cumulative stress and minimizing risks can prevent ergonomic injury. Using engineering methods to address comfort issues these risks can be minimized. Mr. Otto feels that risks could also be minimized if a stretching program were in place For employees and also establishing a maximum time an operator can be allowed to operate without receiving a break.

Some companies have an Ergonomics team to insure that the workplace is a safer and better place to work. This team can also help to increase production and reduce the health risk of work. Above all else proper training is the most important aspect of Ergonomics.

End of presentation: 12:00 A.M.

There were no questions

May 12/99

1:00 P.M.

Cavotec, Electric Cable Reels

Risto Toulcola

Log handling cable reel installation depends on the fullness of the reel. An empty reel needs three times the rotational speed versus the full reel. To meet the different requirements for long track and high speed, frequency controlled drive units are now available.

The types of clutches for cable reel are Conventional Permanent Magnet Clutch, Eddy Current Clutch, DTC Clutch, Hydraulic Clutch, and Director Torque Control Clutch.

Power cables are good for 14% of their breaking strength. The cable life should be at least 5 years.

End of presentation: some discussion took place 2:00 P.M.

Election of officers for the year 2000 and site.

Co-chair for the U.S. side John Peak nominated and accepted.

Treasurer for the U.S. side no nominations position left vacant.

Chairperson for Canadian side Ken Landry nominated and accepted.

Treasurer for the Canadian side no nominations position left vacant.

Site for the next meeting was discussed and Timmons Ontario was picked. Gary Otto to send Ken Landry a contact name for host site.

Elections and site closed at 2:30

Review of mill videos 2:45 to 5:00 P.M.

Meeting ended for the day at 5:00 P.M.

May 13/99

8:45 a.m.

Andritz Kone Wood Log Porter Cranes

Allan Cameron, Jeff Fish, & Chris Gray

Andritz Kone Wood has training and technical support 24 hours a day and their product support is now world wide. They have worldwide parts compatibility and are customer approved.

Siemens is now making cranes better by reducing electrical contents, such as wiring and electrical components. They have utilized an A.C. Regenerative Drive for the gantry and trolley. It will eliminate D.C. Buss Braking Resistors and give energy savings. The A.C. Drive will also eliminate maintenance of gantry and trolley motors. There will be no blowers or brushes.

Siemens has now enabled high-speed communication between Gantry control house and operators cab with improved Fault Monitoring System. This system gives real time representation. They have also enabled for true step-less speed control.

Mr. Fish explained that D.C. Buss Configuration is more effective than pulse resistor braking and is reduced in size, making it more compact. The D.C. Hoist Drive has built in crane logic, high speed communication, and auto tuning.

Mr. Gray explained that the TIA system is flexible and adjustable to meet crane use. It is also universal. Solutions for the new millennium are network crane control, very reliable connectors from gantry to trolley, and expanded diagnostics using MS Windows. The totally integrated concept allows for everything to be tied together by universal equipment that is easily expanded.

The crane controllers are the heart for both the gantry and trolley control systems. The Compact crane controller saves panel space, has smaller control panels, and saves on weight. There is also room for expansion on this modular system.

The Human Machine Interface (HMI) has a wide variety of ways to provide information to operators and others that need it. There are three different types of HMI’s; Classes 1, 2, 3, with Class # being the most sophisticated. The TP27 are graphical touch models with a large viewing area with a pop up keyboard. The TP27 is an ergonomic specialty, which is easily modified. All information is stored on the touch screen, there is no PLC memory and it is easier to maintain.

The system is connected using Profibus. Profibus is the leading "fieldbuss" network that is also known as the purple hose. Profibuss is an international standard. It is easy to use, high speed, reliable, and has fast programming. There is one database for everything. The benefits of the Profibuss are astronomical.

End of Presentation: 2:40 P.M.

May 13/99

9:45 A.M.

Peiner USA (Grapples)

Dennis Porter

SMAG is the leading manufacturer overseas of the large grapples or grab. They specialize in creating the particular grab that any company may need. They have more than 40 years of experience and maintain representations and service agencies on all 5 continents. SMAG offer consultation, service and spare parts supply around the clock. Their inspections and approvals are carried out according to the rules and regulations of all international classification societies.

SMAG is increasing the handling rates by innovative engineering and design. In Europe, the grabs start at 2 sq. ft and progress up to 90 sq. ft. in size. The largest grab is 90 sq. ft. In Norway. It has an oil capacity of only 90 gallons.

End of Presentation: 10:15

There was some discussion

May 13/99

10:45 A.M.

J.R. Merrit Controls (Operator Seating)

Doug MacKay

J.R. Merrit Controls has made several changes and improvements that are now available for the operator seating. Improvements have been made for the overall comfort and safety of the operator.

There is improved visibility for proper handling of the load. The chair itself has been adapted to the operator’s body. The seat has several adjustments for comfort and circulation. The armrests slide back and forth, in and out, for elimination of fatigue. After the operator sits in the chair, they can dial in their weight for chair adjustments. The chair slides back and forth for easy control alignment. All of the functions are manual, but can be motorized. The consoles can also be motorized. They build chairs to meet your requirements.

A leather boot can be offered over the rubber boot. They are getting feedback that customers were having problems with the rubber boots. The T- handle is also available. The chair can be reclined for emergency situations.

Some questions and answers were exchanged at this point.

End of Presentation: 12:00 A.M.

May 13/99

1:00 P.M.

Wire Rope Industries (cables)

J.H. (John) Goacher

Wire Rope Industries has 110 years in their field. They have specialized testing equipment available to simulate actions of a crane. A wire rope fatigue machine has been constructed to test their ropes and the competitor’s wire ropes. They determine customer’s needs to solve wire rope problems.

They conducted surveys on 6 strand, 8 strand, and multi-part overhead lines. The Surelift Conclusions of the survey determined that the wire life was most important to the customers. Other concerns were the cost and service criteria. The Surelift project objective was to supply a full arrange of outperforming crane wire ropes.

As a result of their project, they constructed the Dy-Pac Strand. The Dy-Pac Strand has a smoother outside and more compact wires. It’s more flexible and stronger. They also developed a high performance lubricant. Several tests were ran on the lubricant and it was determined to be the best and most cost efficient. Also, a plastic enhancement that coats the inside of the wires has improved the core protection and strand support. The Dy-Pac has 15% more cycle life.

Overall, the customer will have less maintenance, and will spend less money. Damage to the wire ropes will be apparent on the outside before it ever reaches the inside. Plastic inside rope can withstand heat up to 100 degrees F and as cold as -40 degrees F.

Presentation was followed by some questions and answers.

End of Presentation: 1:45 P.M.

May 13/99

1:45 P.M.

Tribco ( brakes pads and clutches)

Nicholas E. Bade

Tribco specializes in making brakes out of a material called Kevlar. Kevlar is five times stronger than steel. Kevlar is an expensive material and is two to three times more than what a customer is used to paying, but Kevlar will have less downtime and it lasts longer. When a brake is made out of Kevlar, it will last three times longer. Tribco will strip, reline, or fabricate any brake-lining that a customer has.

Kevlar is not a rigid material, so therefore it cannot be molded. They had to engineer a metal core. Water will not damage this product, but if oil spills on the product it will then lose it’s co-efficient of friction. Stop ability is in the range of 3.6. These types of brakes are not available for automobiles.

Some questions and answers at this point.

End of Presentation: 2:30 P.M.

May 13/99

3:00 P.M.

Mack Grapple

John Loftin and Bob Childs

Mack Grapple began 56 years ago in Minnesota. They have constructed a new grapple that is a low profile and is available in sizes %0 sq. ft. To 100 sq. ft. These grapples will allow you to deck 2 more feet in height. They now have parts available on the Internet. If a customer has any problems with a Mack Grapple, a technician will come to you.

End of Presentation 3:45 P.M.

May 13/99

3:45 P.M.

Seattle Crane and Hoist

Henk Versteege

Wheel alignment on a portal crane is exceptionally important. If there is improper alignment the cost is very high. A single gantry wheel replacement could cost anywhere from $6,000 to $10,000.

Serveral things could cause a premature failure. If a gantry wheel is out of alignment or boogies are out of alignment a premature failure can occur.

Guide rollers or side rollers on a gantry can be effective for reducing wear, but misalignment will then be transferred to the guide rollers. They can in turn wear out very rapidly. Misalignment of a gantry wheel can cause other problems as well.

A wheel alignment is needed to correct the problem. A tracking of the wear rate over time is needed to help in the correction of wear problems. By stretching a piano wire the full distance and taking measurements you can determine what needs to be corrected. The boogie or wheel will then have to be adjusted for correction. Whether or not rail is perfectly straight the measurements will give you a guide on correction. The piano wire establishes a straight line for comparing measurements.

End of Presentation: 4:30 P.M.

May 13/99

4:30 P.M.

Suggested topics for next year

Track companies

Bass electronics

Ergonomics ( new stuff)

Someone on posture

Gessman Chairs

Radios (Motorola)

Inventory, trucking procedure, fire protection

Crane automation

Tie and Ballast

Safety Committee report

Bring daily check list

Accidents

Round table discussions

Have meeting second week in May

Fire hazard issues (tapes and pictures)

May 14/99

Tour Mead

8:30 A.M.

The group left the hotel parking lot by bus to tour Mead Containerboard. At site the group was divided three ways for tours of the Portal Cane, Woodroom facility and the bark handling system. All tour were well received and very informative.

Following the tour Mead hosted the group to a B.Q. steak and trimmings lunch. After the meal personnel from Mead entertained questions on their operation.