400/100/10T Bridge Crane for Hydropower Plant

Huayuan made a 400/100/10T Bridge Crane for a hydropower plant and carried out installation successfully. This crane has a 400-ton main hook, a 100-ton auxiliary hook, and a 10-ton electric hoist. The project faced significant obstacles, including a single main beam weighing 42 tons, an installation height of 28 meters, and a confined site. The solutions applied and the results achieved offer valuable insights for engineers and project managers working in similar environments.

Challenges of Installation in Confined Spaces

Hydropower plants often have tight spaces due to existing infrastructure and terrain constraints. In this case, the installation site was confined, limiting the movement of cranes and other heavy machinery. The main beam alone weighed 42 tons, requiring careful handling to avoid damage or accidents.

The installation height of 28 meters added complexity, demanding equipment capable of precise vertical lifting. Additionally, the project required multiple lifting capacities: a 400-ton main hook for the heaviest components, a 100-ton auxiliary hook for secondary loads, and a 10-ton electric hoist for smaller parts. Coordinating these elements in a restricted area required innovative approaches.

Innovative Solutions for Complex Installation

The project team developed a multi-step plan to address the challenges:

• Segmented Transportation and On-Site Assembly

Transporting the main beam as a single piece was impractical due to its size and weight. Instead, the beam was divided into manageable segments. These segments were transported separately and assembled horizontally on-site. This approach minimized transportation risks and allowed for better control during assembly.

• Overall Hydraulic Lifting into Place

After horizontal assembly, the entire beam was lifted hydraulically into its final position. Hydraulic lifting provided smooth, controlled movement, essential for aligning the beam accurately at a height of 28 meters.

• Single Lift Using a 500-Ton Crawler Crane

To ensure precision, a 500-ton crawler crane performed a single lift of the assembled beam. The crane’s capacity exceeded the beam’s weight, providing a safety margin. The connection error of the main beam was kept under 2 millimeters, demonstrating exceptional accuracy.

• Intelligent Load Testing with Cast Iron and Concrete Blocks

Before commissioning, the installation underwent a rigorous load test. The team used 470 tons of cast iron blocks combined with 170 tons of concrete blocks to simulate operational loads. This intelligent testing method verified the crane’s performance and the structural integrity of the installation.

Results and Project Impact

The load test lasted 72 hours and was passed on the first attempt, confirming the reliability of the installation and the equipment. The project was completed and handed over to the owner five days ahead of schedule, a significant achievement given the complexity and constraints.

This success highlights the importance of detailed planning, the use of specialized equipment, and innovative assembly techniques in hydropower plant projects. The ability to transport large components in segments and assemble them on-site can reduce risks and improve efficiency. Hydraulic lifting and precise crane operation ensure safety and accuracy at great heights.