Inspection
& Diagnostic
1. Plantwide Structural Inspection
General and detailed structural inspections of approximately 3,000 items including hot metal cranes
and crane runways, EOT mill cranes and runways, ore bridges, buildings, electrical transmission towers
and conveyor structures. The inspection program is plant-wide and is scheduled according to our clients corporate standards. Emergency structural inspections are performed on an "on-call" basis. Numerous engineering
projects have been performed as a result of the inspection recommendations (including runways, cranes, bridges, loading floors, etc.)
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2.
Fire Damage Assessment of Metals Industry Facility
Engineering
Services for Inspection and Assessment of Fire-Damaged
Industrial Structures and Cranes and at a Metals Industry
Facility
Responding on very
short notice, Globex dispatched a team of engineers and inspectors
to assist a metals industry client with the assessment of structural
damage that occurred during a devastating fire at their production
facility. Although the primary focus was the structural integrity
of the buildings and crane runway structures, Globex specialists
also examined those cranes damaged in the fire to determine the
extent of the damage and to identify the measures necessary to
restore these assets to a fully operational state. In the immediate
aftermath of the fire, Globex provided essential guidanceto the
client, and related entities, as to the extent of the damage and
the manner in which the structural repairs and restoration effort
could proceed. Of special concern was the safety of the repair
forces during the initial phases of the restoration for the main
building structures. In addition to assessing the physical integrity
of the fire damaged items, Globex also provided guidance for the
execution and interpretation of the dimensional surveys of the
buildings and cranes, which was necessary to assure that these
items would not only be restored to a state of physical integrity
but that they could also be returned to a state of operational
reliability. As restoration efforts continued, the focus shifted
to the repair or replacementof production equipment and machinery
including the standard and specializedoverhead cranes. For these,
Globex examined the damaged equipment and identifiedthe various
components in need of attention. These included the structural,mechanical,
and electrical aspects of several overhead cranes, some equippedwith
sensitive features for automated operation. At the conclusion
of the structural restorations, Globex was called on to confirm
that the necessary repairs had been completed prior to occupancy
of the buildings for the resumption of production operations.Working
in conjunction with the client and its restoration contractors,
Globex provided the on-demand services necessary to assure that
this metal producing facility was able to resume operations in
a relatively short period after the fire which had completely
destroyed its productive capacity.
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3.
Cable Winding Machine
Non-Destructive
Testing and Evaluation of the Take
Up Head on a Cable Winding Machine for a Metals Industry
Client
Provided engineering
analysis and consultation to the client in an effort to confirm
the design adequacy of the take-up head and related components,
connections, and mechanisms. Globex obtained drawings from the
client and the machine's manufacturer as well as conducted an
on-site examination of the components of interest. This examination
included visual means as well as non-destructive examination (NDE)
through the use magnetic particle testing. Additionally, Globex
critically analyzed the several components of interest, performing
calculations to determine the level of material stress with respect
to the allowable values for same. Because the machine was not
produced domestically, the material properties were obtained from
international standards. Based on the field findings and the results
of the stress analysis, Globex provided the client with recommendations
for further action in their efforts to achieve a higher degree
of safety and operational reliability.
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4. Blast Furnace:
Skip Hoist System
Complete
field inspection for documentation of existing installation
of equipment and condition. Analysis of entire skip
hoist system for increased car load capacity including
incline motors, brakes, gear trains, drum, skip sheaves
and rope system Verification of the adequacy of electrical
drive control system. Provided duty cycle analysis utilizing
three different methods: horsepower second; RMS horsepower
torque and watts loss calculations. Preparation of complete
design and detail drawings for new skip hoist system.
Provided construction management and consultation services
during fabrication and erection.
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5. Coil Pickling Building Crane
Detailed inspection of runway structure to determine
deterioration caused by corrosive environment utilizing
ultrasonic thickness gauge measurements.Analyzed runway
structure for reduced capacity due to section deterioration
and duty cycle service.
Conceptualized a series of reinforcement alternatives
for increased runway capacity taking into account the
existing building conditions including utility hangers
and auxiliary equipment. Provide plans, specifications
and cost estimates.
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6. 180 Foot Semi-Gantry Pulp Unloading Crane
Inspected the crane to determine the extent of structural
and mechanical damage caused by dynamic forces during
the unloading operation. Observed the crane during normal
operation to determine the extent of dynamic loadings
caused by acceleration, braking, impacting bumpers and
bridge skewing. Performed a complete structural analysis
of the crane including the trolley frame, bridge girder
and supporting tie rods, gantry legs, portal frame,
and the elevated bridge rail support system to determine
structural adequacy. Recommended methods for eliminating
skewing and the associated wheel and rail wear including
upgrading the trolley and bridge drive systems. Investigated
the potential operational benefits of several proposed
crane modifications including removal of an excess portion
of the bridge cantilever and replacement of bridge girder
supporting tie rods with a rigid steel framework.
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Design
& Analytical
1. Dry Dock
Portal Cranes
Provided complete design including detailed installation drawings
and cost estimates for replacing the air controlled band brake
systems with hydraulic controlled shoe brake systems, for the
boom, main and auxiliary hoists. Prepared complete design and
installation drawings for replacing the air controlled band brake
system with a hydraulic controlled shoe brake system. Provided
on site inspection of cranes to determine the existing condition
and to verify existing engineering information. The brake conversions
required unique engineering solutions due to the physical space
available. Globex designed an additional primary pinion shaft
with new structuralsupports to mount the new brake wheels. These
four (4) portal cranes are classified "special purpose" as they
lift nuclear loads. The brake replacement design engineered by
Globex Corporation met and exceeded the Government SPS criteria
and was subsequently approved by NAVFAC. Back
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2. Support for the Installation of (8) Crane Runway Girders
Complete structural analysis of both crane runway systems
for increased overhead crane loading capacity. The
analysis was completed using computer finite element
analysis techniques. Components analyzed included: crane
runway girders, runway and building support columns,
column foundations and all critical structural connections.
Preparation of complete detail, arrangement and installation drawings,
specifications and cost estimate to allow fabrication
of the new runway girders. Provided fabrication and
installation/erection engineering support, including
fabricator site inspections, quality assurance, erection
drawings and procedures. Provided construction management
services, bid review, assisted erection contractor and
resolved any point in question during erection process. Provided
as-built drawings. Back
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3. Inspection of 4 Cranes in Radiation
Controlled Area
Cranes and runway were located in a radiological controlled
area. This contract required the usage of qualified
radiation workers to perform all field surveys.Surveyed
entire runway for rail straightness, elevation, parallelism
and span, inspected runway for rail wear, structural
damage, and other problems. Inspected all cranes for
squareness and alignment, bridge wheel replacement as
well as general mechanical, electrical, and structural
repairs. Evaluated electrical control systems, bridge
drives, runway feedrail systems, and other proposed
modifications under consideration by NRF management.
Prepared complete reports on all findings which included
our evaluations, conclusions, and recommendations. These
reports included conceptual drawings describing proposed
facility and crane repairs and upgrades. A detailed
cost analysis was also provided for proposed facility
and crane repairs and modifications.
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4.
Crane Runway Survey
Instrument
Dimensional Survey of a Crane Runway at Major Steel
Producer
Responding on short
notice to the client's request for assistance,Globex performed
an instrument dimensional survey of the crane runway in their
coil shipping building. The client had recently installed a newly
purchased crane on this runway and was experiencing operational
difficulties with its bridge tracking. Globex was tasked to identify
the cause of the problems. From the survey results, Globex identified
several problems with the runway structure as well as the crane
itself and provided the client with recommendations to remedy
these.
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5. Crane Runway Analysis
Complete structural analysis of both crane runway systems for
increased overhead crane loading capacity. The analysis was completed
using computer finite element analysis techniques.Components analyzed
included: crane runway girders, runway and building support columns,
column foundations and all critical structural connections. Preparation
of complete detail, arrangement and installation drawings, specifications
and cost estimate to allow fabrication of the new runway girders.
Provided fabrication and installation/erection engineering support,
including fabricator site inspections, quality assurance, erection
drawings and procedures. Provided construction management services,
bid review, assisted erection contractor and resolved any point
in question during erection process. Provided as-built drawings.
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6. Quality Assurance for the
modification of (2) Solid Rocket Motor Assembly Cranes
Provided quality assurance services as required to ensure
that all work was accomplished in conformance with the
design drawings and specifications. The services
consisted of reviewing all design documents and, based
on same, developing detailed checklists and other forms
for recording that required tasks had been performed
and recording the values of all parameters measured. The
checklists and other forms were complex, comprehensive
and provided installation personnel and inspectors with
a detailed roadmap to ensure that all necessary strictures
were complied with. Also provided field support
engineers to perform quality assurance oversight of
installation work. The modifications to the cranes
involved mechanical, structural, electrical, and PLC
systems and components. Of particular note is that
much of the work involved the installation, start-up
and checkout of a fiber-optic communication system between
the various elements of the cranes' control systems
including the PLC, drive controls, command consoles,
and various sensors located throughout the cranes' structures
and systems.
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7. Air Controlled Brake Systems
Provided
complete design including detailed installation drawings
and cost estimates for replacing the air controlled
band brake systems with hydraulic controlled shoe brake
systems, for the boom, main and auxiliary hoists. Prepared
complete design and installation drawings for replacing
the air controlled band brake system with a hydraulic
controlled shoe brake system. Provided on- site
inspection of cranes to determine the existing condition
and to verify existing engineering information.
The brake conversions required unique engineering solutions
due to the physical space available. Globex designed
an additional primary pinion shaft with new structural supports
to mount the new brake wheels. These four (4) portal
cranes are classified "special purpose" as
they lift nuclear loads. The brake replacement
design engineered by Globex Corporation met and exceeded
the Government SPS criteria and was subsequently
approved by NAVFAC.
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Engineering
& Consulting
1.
Expert Witness Analysis
Consulting
Services for Expert Crane Engineering
Provided forensic
consultation to a legal firm for their case involving a crane-related
workplace injury. Reviewed the information related to the case,
examined the crane, and advised the client (legal firm) as to
the best course of action to establish the actual cause of the
incident. Based on Globex's advice, the client was able to achieve
an early (out-of-court) settlement in their favor.
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2. Solid Rocket Motor Assembly
Cranes
Investigated various means to safely lower suspended
crane loads in the event of power failure and other
emergencies which would render the hoists inoperable. Provided
analyses and recommendations based on capability with
respect to load handling and feasibility with respect
to retrofit onto the existing cranes. The methods
selected were capable of accomplishing the required
load handling independently of the cranes' normal power
and control systems. Developed the methods for load
handling. Prepared the drawings, specifications,
and other design documents required for the customer
to purchase and install the items required for retrofit
onto the cranes.
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3. Crane Modernization
Turn-key engineering services for relocation of a 35 ton capacity
semi-gantry crane from at a customer facility. The semi-gantry
crane was converted from AC to DC operation, and structurally
modified to fit in the new location. Inspection to determine the
condition of the existing mothballed equipment at a customer site
to ascertain feasibility and project commitment for equipment
relocation. Conversion of the crane from AC to DC operation including
motor and brakes changes, control system, conduit layouts and
installation of a festoon system. Converted the trolley from the
stiff mast to a reeved lifting system.Provided complete construction
specification, drawings and cost estimates for both semi gantry
crane and runway installation. Globex Corporation designed a complete
new runway system including piers and foundations, columns, runway
girders and electrification system for the elevated portion of
the runway, and the rail foundation and rails for the gantry leg
portion of the runway. Provided construction management and consultation
services during fabrication and erection of the crane and crane
runway system. Back
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4. 165 Ton Derick
Engineering technical services for mechanical, electrical, and
structural inspection of erection of the 165 ton stiffleg derrick.
Work involves the inspection of the crane assembly, operation,
and inspection of components. Specific inspections include the
monitoring of field welding and non-destructive testing, high
strength bolting verification, painting and installation and connection
of wiring to insure that the construction work complies with contract
plans and specifications.The erection complies with contract plans
and specifications. The erection work performed by private construction
contractors. Back
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Project
Management
1. 50/15 Fuel Handling Crane
Provided shop inspection, test support, and design evaluation
for the crane's conformance with purchase specifications
and industry standards. Evaluated design documents produced
by the crane manufacturer and significant equipment
vendors. These included drawings, specifications,
O & M manuals and PLC program printouts. Prepared
and submitted reports for customer review. These
listed deficiencies, inconsistencies and items of nonconformance.
Met with client personnel and personnel from the customer's
departments and outside organizations responsible for
the operation and maintenance of the cranes. These
meetings were at the manufacturer's location and held
in preparation for the inspection and testing activities
which were to follow at the production facility. Reported
to, advised and coordinated inspection and test activities
with these personnel. Inspected the crane in the manufacturer's
facility with emphasis on its conformance to purchase
specifications, design documents and industry standards
including materials used and execution of the work. Particular
concentration was in the area of wiring practice, drive
controls installation, and software functions. Reports
were prepared and submitted for customer review. These
listed observations made during the inspection and detailed
those deficiencies and items of nonconformance which
were discovered during the inspection. At the manufacturer's
fabrication facility, witnessed the testing of the various
functions associated with the power and control of the
hoist and travel drives on the crane. Prepared
and submitted reports of same for customer review.
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2.
Crane Procurement
Provide Assistance
for the Purchase of New 25-ton Crane
Provided assistance
to a metals industry client in determining the most advisable
crane features with respect to design, construction, and performance
as appropriate for the crane's operating environment and production
duty. This allowed the client to achieve the best balance between
the installed cost (purchase price plus installation) and thecrane's
functionality, ease of maintenance, and operational reliability.
Advised the client in its dealings with prospective suppliers,
especiallyin its evaluation of vendor proposals. The emphasis
was on areas of technical merit, including conformance to the
applicable codes and standards. Individual areas issues addressed
included the structural, mechanical and electrical aspects of
the crane as well as the design and production capabilitiesof
the prospective crane supplier including their ability to produce
the crane within the time required and with an adequate level
of quality assurance. During this project, Globex consulted with
the client's engineering, production andmaintenance personnel
to determine features and capabilities essential for thecrane
as well with prospective suppliers to ensure that these features
andcapabilities would be provided.
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3. Fiber Optic Control System
Determined feasibility and most appropriate means of
converting existing crane control system to fiber optic
connection for signal transmission. Evaluated available
fiber optic equipment for application to overhead crane
control. Crane control system included both onboard
and remote control devices.New fiber optic system improved
signal transmission integrity, reduced system hard wiring,
and enhanced control system performance.
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Projects