Technical Description: FEEDER SERVER® Standard

FEEDER SERVER® Standard
TECHNICAL
DESCRIPTION
Rail Mounted Ship-to-Shore Container Gantry Crane 40t x 40/20/16m
PROJECT NO: 27018/17
LOCATION: Hai Phong Dinh Vu / Vietnam
Customer: MIPEC Port

The FEEDER SERVER - a Ship-to-shore crane optimised for handling Feeder Vessels
Document: FS Technical Description Standard Offer No.: 27018/17

KOCKS IS A MEMBER OF KRANUNION Date: 21.02.2017
TABLE OF CONTENTS
1. MAIN PARAMETERS ........................................................................................................ 3

1.1 TECHNICAL DATA ................................................................................................... 3
1.2 CALCULATION AND CLASSIFICATION ................................................................. 8
2. TECHNICAL DESCRIPTION ............................................................................................. 9
2.1 STRUCTURAL STEELWORK .................................................................................. 9
2.2 SURFACE PREPARATION AND PAINTING........................................................... 12
2.3 MECHANICAL COMPONENTS .............................................................................. 13
2.4 MAIN HOIST MECHANISM .................................................................................... 13
2.5 BOOM HOISTING MECHANISM ............................................................................ 15
2.6 TROLLEY TRAVEL DRIVE ..................................................................................... 16
2.7 GANTRY TRAVEL MECHANISM ........................................................................... 17
2.8 CABINS AND ELEVATOR ...................................................................................... 18
2.9 TELESCOPIC SPREADER..................................................................................... 19
3 DOCUMENTATION ......................................................................................................... 20
3.1 CRANE DOCUMENTATION .................................................................................. 20
3.2 NOTICE .................................................................................................................. 20
4 DELIVERY AND ERECTION ........................................................................................... 21

1. MAIN PARAMETERS
The design and layout of the FEEDER SERVER is optimized to ensure economic
handling of 20, 40 and 45ft ISO containers on Panamax container vessels.
The clearance under the portal cross beams permits the unobstructed traffic of trucks,
trailers, forklifts or straddle carriers in the container yard. The crane is designed to
work in close proximity with other FEEDER SERVER cranes during parallel
unloading/loading of vessels.
The hoist winch assembly and boom hoist assembly plus the associated electrical
components are installed in separate housings which are pre-tested before leaving
the production works.
The crane can also work with 50t load under hook beam.
1.1 TECHNICAL DATA
For general dimensions please refer to the enclosed project drawing 27018-2017-000-0
 Lifting Capacity
On the ropes during container operation 54 t
Below telescopic spreader 40 t
Option: Below hook beam 50 t
 Outreach
Waterside outreach from centre of waterside (WS) rail 40 m
Landside backreach from centre of landside (LS) rail 16 m
 Lifting Height
Maximum lifting height above WS rail level to bottom of spreader 30 m
Maximum lowering depth below WS rail level to bottom of spreader 14 m
 Portal Dimensions
Rail gauge 20.0 m
Clearance under portal beams 14.0 m
Clearance between legs 17.05 m
Length of crane between uncompressed buffers, approx. 26.05 m

 Crane and Trolley Wheels
Crane rail A100
Crane wheel diameter - gantry travel WS/LS 630 mm
Total number of crane travel wheels 32
Number of crane wheels on WS / LS 8 / 8 per corner
Number of driven crane wheels 4 per corner
Trolley wheel diameter 400 mm
Total number of trolley wheels, all driven 16
 Speeds/Accelaration
Hoisting speed with 40t rated load under spreader 50 m/min – 1,67s
Hoisting speed with empty spreader 120 m/min – 4,0s
Trolley travel speed 150 m/min – 5s
Gantry travel speed 45 m/min – 5s
Boom retracting/lowering time (each direction) 5 min - 2,5s
 Wheel Loads
a) Crane in operation per DIN 4212, with horizontal boom
Max. vertical wheel load, WS rail 380 kN
Max. vertical wheel load, LS rail 300 kN
b) Crane out of operation, with raised boom and 45 m/sec wind speed
Max. vertical wheel load, WS rail 312 kN
Max. vertical wheel load, LS rail 389,5 kN
 Dead weights
Design weight of the crane (without spreader and ballast) 585.7 t
Counter Weight / Steel plates 36.9 t
Spreader deadweight (without load) approx. 9.5 t
Total crane weight with empty spreader, approx. 632.1 t
 Main power supply to the crane

AC supply xx KV, 3-phase, 50 Hz
 Ambient climatic conditions

Ambient temperature -0°C to + 45 °C
Relative humidity up to 96 %
Maximum wind speed during crane operation up to 20 m/s
Maximum wind speed during crane out of operation up to 45 m/s

Electric:
Voltages, Supplies
Feeding voltage : xx kV 3ph+PE +/- 10%; 50Hz +/- 1% acc. DIN EN50160
Main drive motors: 400V, 50Hz, 3ph.
Auxiliaries, static loads: 400V, 50Hz, 3ph.
Lighting, Auxiliary: 230V, 50 Hz, 1ph.
Control voltage: 230V, 50 Hz, 1ph.
Control voltage, PLC : 24V DC, 230V AC
Voltage solenoids, valve: t. b. a. (to be advised)
Motors
Construction : Standard AC squirrel cage motors for frequency
inverter operation
Manufacturer : Wölfer, Germany
Design : The motors are specially designed and manufactured for
lifting appliances
Hoisting Trolley Gantry Boom

Qty 2 16 8 1
Type 280L-6b Geared Geared 200L-4b
motor motor
Power 250 kW 9,2KW 22 kW 75 kW
rating (kW)
Duty cycle S3-60 % S3 – 60 % S3-40% S3-40%
(%-CDF)

Main Drive Inverter system
The main motors will be feed by 3-phase, pulse width modulated, sine wave
shaped inverters with full digital driver/regulator. A PLC communication interface
will be provided for each inverter. Additional hard wired control signals ensure a
safe and reliable operation.
Step less speed control with load sharing (constant torque) from nearly zero to the
rated speed will be provided. Load depending field weakening from rated up to
maximum speed will be provided for the hoist drive.
The following inverter will be installed:
Manufacturer Siemens Series Sinamics S120 series

Application
Several AC-motor inverter connected by a common DC bus bar
to the 2Q supply unit and
Regenerative Line power unit
Brake chopper and –resistors
For 4-Q operation
Drive system contains
control unit for control and regulation

sensor module/input (one or more) for encoder
IGBT semiconductor control and power unit
Digital regulation
Line filter or choke partial
Communication interface
Hoist Trolley Gantry Boom
Qty 2 1
Type 6SL3320- 6SL3320-
1TE36-1AA3 1TE33-8AA3
Power rating (kW) 315 200
base current (A) 570 340
Remark/(HxWxD) 2200x600x600m 2200x400x6 Shares with Shares with
m 00mm Hoist Trolley
SMART Line Bake unit Brake resistor

unit 400V
Qty 1 4 4
Type 6SL3330-6TE41 6SL3000 Special
Total power (kW) 800 200
at 400 V
Remark (HxWxD) 2200x600x600 Build in type

1.2 CALCULATION AND CLASSIFICATION
The crane is designed and built in line with current FEM standards.
FEM 1.001 3rd edition 1998 rules for the design of hoisting appliances;-
 Booklet 2 Classification and Loading on Structures and Mechanism.
 Booklet 3 Structural Design/Stress Calculation.
 Booklet 4 Fatigue and Choice of Mechanical Components.
 Booklet 5 Electrical Equipment
 Booklet 7 Safety regulations for cranes
 Booklet 8 Test loads and Tolerances
 Booklet 9 Appendixes and Comments to Booklets 1 to 8
 Steel Structure
In accordance with FEM 1.001, 3rd Edition 1998
FEM Classification
Structure
40 t operation Class of use U7
Spectrum class Q3
Machine group A8
 Mechanism
In accordance with FEM 1.001, 3rd Edition 1998
FEM Classification
Mechanisms
Hoisting Class of use T8
Drive, 40 t Spectrum class L3
rated load Machine group M8
Trolley Travel Class of use T8
Drive, 40 t rated Spectrum class L3
load Machine group M8
Gantry Travel Drive Class of use T5
Spectrum class L3
Machine group M6
Boom Luffing Drive Class of use T5
Spectrum class L3
Machine group M6
 Applicable Standards and Regulations

The crane will be designed in accordance with:
 German Accident Prevention Act
 German Machinery Protection Act

 VDI-Guide-Lines
 DIN / FEM / ISO Standards
 European Crane Standard EN 60204/32 Crane Electric
 Recommendations for the construction of harbour cranes.
 Local safety regulations
2. TECHNICAL DESCRIPTION
The design of the crane incorporates optimum operating practice, giving;

 Trouble-free operation
 Low weight
 Reduced wind surfaces
 Easy maintenance, erection and accessibility
2.1 STRUCTURAL STEELWORK
2.1.1 General
For the welded steel structure (load- bearing

members) materials in accordance with DIN EN
10025 or equivalent (e.g. JIS or ASTM) are used.
Steel: S355J2+N, S255J2 or equivalent (e.g. JIS,

ASTM).
The structural steelwork will be mainly of welded

box girder and tubular construction and
comprises:
 Bogies, Portal, Pylon

 Bridge Girder
 Boom
 Forestays
 Trolley, Operator´s Cab, Checker´s Cab
 Main Hoist House and Boom Hoist House
 E-House and Transformer House
 Stairways, Ladders, Platforms and Walkways
2.1.2 Bridge Girder

Light-weight Portal Structure
The bridge girder is a welded single box
construction. A walkway is fitted to one side with hand railing on the outer side. Two

stationary slewing cranes fitted with an electrically operated hoist for lowering or
raising the largest unit of equipment required for repair and maintenance work are
provided. Floodlights will be installed under the lower chord of the bridge girder.
Hydraulic buffer end-stops for trolley travelling will be fitted.
2.1.3 Boom
The WS boom is a lightweight box girder

construction with two extended double-T-
profiles at the base. Both sides of each
lower T flange are used as trolley rails.
Hydraulic buffer end-stops for trolley

travelling will be fitted.
2.1.4 Trolley
The crane will be equipped with a self-

propelled trolley with four wheels per Light-weight boom structure
corner.
The trolley frame is designed of a rigid welded steel structure and accommodates the
trolley drive and all necessary rope sheaves.
The trolley wheels run on the surface

of the boom’s lower T Flange.
The operator's cabin is a separate unit

and supported on four wheels with
guide rollers. The cabin is connected
to the trolley by a steel frame at the
landside of the trolley’s structure.
Self-propelled Trolley running beneath the mono-box girder

2.1.5 E-House
The electrical equipment is safely installed in cubicles located in a separate

weatherproof air- conditioned unit located on top of the bridge girder.
A smoke detection system and fire extinguishers will be installed.
E-House Arrangement
2.1.6 Stairs, Ladders, Platforms and Walkways
Stairways, ladders and walkways will be provided in sufficient numbers designed in

accordance to the valid local rules and regulations and German Accident Prevention
regulations.
All necessary regular maintenance access points are fitted and equipped with
platforms providing a safe and comfortable working environment. The main stairs /
platform and walkways are 600mm wide
The boom and bridge girder walkways are fitted with anti-skid coating.

2.2 SURFACE PREPARATION AND PAINTING
Due to the wet and salty port environment, the working atmosphere will be
aggressive. Therefore, special attention will be given to the selection of materials and
corrosion protection.
The following painting schemes will be applied to the crane:
2.2.1 Exterior surfaces
De-rusting of the steel components according to SA 2½
 1 coat of primer on a 2-component epoxy zinc phosphate basis, DFT 70µm

 1 intermediate coat on a 2-component epoxy iron-mica basis, DFT 90 µm
 1 finish coat on a 2-component polyurethane basis, DFT 90 µm
 Total DFT approx. 250 µm in accordance to DIN EN ISO 12944-5.
 The color of the finish coat to be agreed upon.
2.2.2 Interior Surfaces
A two layer system on a 2-component epoxy basis will be applied to all accessible
internal structural steel surfaces, DFT 200µm.
Non-accessible internal surfaces will be seal-welded only.
2.2.3 Access Structures
Stairways, ladders and handrails will be hot dip galvanized; open mesh floorings and
cable trays will be hot dip galvanized. Safety painting is executed in accordance with
prevailing safety regulations.
2.2.4 Components
Components supplied by sub-contractors will be painted for outdoor use, compliant

with the conditions and will not be repainted to any specified color by ourselves prior
to delivery.
Repair of transport and assembly damages will be carried out at site.
The warranty for the protective paint system is based on DIN EN ISO 4628-3 – Ri 3.

2.3 MECHANICAL COMPONENTS
All machinery is designed and manufactured in accordance with the latest mechanical
handling engineering developments, using the most suitable material. Standardized
components will be used as far as possible with emphasis on uniformity and
simplicity.
2.3.1 Anti-friction Bearings
Bearings with minimum rated service life time will be selected in accordance to FEM.
 Life time of bearings for main drives: 25,000 hrs (in accordance with FEM)
 Others bearings: 12,500 hrs (in accordance with FEM)
2.3.2 Brakes
The main drive systems are equipped with the following brake systems:
 Main hoist: disk brake and hydraulic safety brake.

 Boom hoist: double shoe drum brake and hydraulic safety brake.
 Trolley travelling and gantry travelling: motor disk brakes.
Selection in accordance with FEM standards.
2.3.3 Crane Travelling Wheels
Travelling wheels are of high quality cast steel. Design and mounting of crane travel
wheels in accordance with: DIN 15 078 and DIN 15 079.
Wheel parameters will be selected in accordance with FEM standards.
2.4 MAIN HOIST MECHANISM
The main hoist mechanism will be

arranged on a frame located on the
rear part of the bridge girder and
consists of two motors, two flexible
couplings with brake disc, two disc
brakes, two built-in planetary type
reducers and two rope drums.
Main Hoist Mechanism on the LS Bridge Girder

Main Hoist Machinery House Arrangement
Main Hoist Rope Reeving Scheme (similar)

2.4.1 Trim, List, Skew
Trim function can be activated by opening the mechanical clutch arranged between
both hoist rope drums. Then the hoisting drums can be driven independently.
List and skew function act via the rope pulleys on the top of the LS bridge girder and
by means of two electrically operated spindle drives.
2.4.2 Overload Protection
The hoisting mechanism will be equipped with an electro-mechanical load limiting

device in accordance with the regulations for prevention of accidents as described in
the electrical specification. This device protects the hoisting mechanisms from
overloads, i.e. cuts-off the hoist gear in lifting direction when exceeding the admissible
total load on the ropes.
The load indicator will give audible and visual indication to the driver when the lifted
load exceeds the nominal load including the dead weight of the spreader.
2.4.3 Emergency brakes
Four emergency brake clamps, which operate directly on the rope drums, will be
installed. The result is faster stop of the lifting equipment and more safety in case of a
gearbox defect.
2.5 BOOM HOISTING MECHANISM
The boom hoisting and lowering mechanism consists of one main drive motor, one
flexible coupling, one double-shoe brake, two emergency brake clamps, one built-in
planetary reducer, and one rope drum.
The rope drum with brake disc consists of rolled and welded plates and is provided
with Lebus shells with right-hand and left-handed grooves. The wire rope is wound in
multiple layers.
Two emergency brakes, acting directly onto the brake disc of the rope drum, will stop
the motion of the boom as soon as 115 % of the nominal drum speed is exceeded.
The brakes are released electro-hydraulically.
2.5.1 Boom Hoist Emergency Drive
The boom hoisting mechanism is equipped with an emergency drive.
The boom hoist drive is controlled by its own control station which is located inside the
boom hoist house.

Boom Hoist Machinery House Arrangement
2.6 TROLLEY TRAVEL DRIVE
The crane will be equipped with a self-driven trolley, with four wheels per corner.
The compact sized trolley travel drives and wheels are easy to maintain.
Each wheel is driven by its own motor-gear combination with integrated brake.
The high number of drive units

provides an optimal load distribution
and power transmission.
The trolley is guided on two pairs of

horizontal guide rollers running
laterally on both sides of each
corner.
Trolley Travel Drive with four driven wheels per corner

Limit switches are fitted for limitation of the trolley travel motion.
All trolley wheels and guide-rollers are fitted with anti-friction bearings.
Trolley Travel Mechanism Arrangement
2.7 Gantry Travel Mechanism
The crane travel mechanism

consists of cast steel double
flanged wheels of high quality
running on anti-friction bearings
arranged in wheel trucks.
The driven wheel trucks is
equipped with one geared motor
each, with integrated disc brakes,
each driving two wheels via an
open gearing.
The travel mechanism is fitted with
drop blocks, rail sweepers and
cellular plastic buffers at the four
Gantry Travel Mechanism
outer wheel trucks.

Arrangement of Gantry Travel Mechanism
2.7.1. Rail Clamps and Locking Pins
Two automatic hydraulically operated rail clamps as well as two pairs of manually
operated locking pins against driving off by storm.
Electrical contacts make sure that the travel drive cannot be operated again before
the pin locking device has been released.
2.8 CABINS AND ELEVATOR
2.8.1 Operator Cabin
The panoramic cabin provides low susceptibility to vibration. The cabin is

ergonomically designed to enable long working time with maximum comfort. The
crane operator has the best possible view of the working range and load.
Cabin interior

2.8.2 Personnel Elevator
An elevator with a payload of 400 kg (4

Person) will be provided at the same leg
as the stairway access.
The lift will operate from ground level to

the entry point of the high level access
gangway to the machinery house with
intermediate landing gates at the cross
beam and operators cabin level access
gangways.
Elevator for convenient access

2.9 TELESCOPIC SPREADER
The spreader will be included in the scope of supply of KOCKS KRANE GmbH.
The adjustable spreader can pick up ISO-standard 20, 40 and 45ft containers.
The spreader will be attached to the pulley blocks of the hoist by pins allowing easy
exchange for an alternative spreader
or other hoisting accessories.
The adjustable spreader consists of

the fixed central portion and the two
extendible lateral parts.
The mechanism to adjust the

spreader from 20ft to 40ft corner
points or vice versa is powered by a
chain drive. The end positions are
secured by limit switches and fixed
stops.

3 DOCUMENTATION
Spreader for 20ft and 40ft Containers
3.1 CRANE DOCUMENTATION
The following crane documentation (incl. maintenance and operation instructions) will
be provided three-fold in English language.
• crane test book • hydraulic and electric diagrams

• overall crane drawing • spare parts list
• operating instructions • technical documentation from sub-
• maintenance instructions suppliers
• lubrication plans and instructions
Final documentation will be provided on CD-ROM in pdf-format.
3.2 NOTICE
KOCKS reserves the right to modify any part of the Feeder Server technic where
experience or technical advances indicate the advisability of such alterations.
Notification to the Buyer will only be given in the case of significant design changes.

4 DELIVERY AND ERECTION
As standard the crane will be delivered and erected on site. Should site or project
require a fully-assembled delivery this can be arranged on request.
Erection, electrical installation and commissioning of the crane will be done by

KOCKS KRANE GMBH or their sub-contractor.
Pre-conditions for an on-site delivery are as follows:
- erection area shall be available approx. two weeks before erection of the crane
- delivery of the crane sections can be made to the site by sea-going vessels, rail,
and road without reloading
- an adequately sized erection site is levelled and hard surfaced
- good access to the site for heavy mobile cranes is provided
- crane track is already laid out
- erection of the crane can be made continuously
- the required certified test weights will be at our disposal free of charge
- erection site plus offices, workshop and mess facilities connected to necessary
services will be at our disposal free of charge
- minimum area for erection must be approx. 100 m x 120 m
- area must be safe and secure
Delivery of fully erect crane (optional)
A Roll On-Roll Off process of the full erected crane will be done using two multi mover
trucks (each below one of the sillbeams) direct onto the pontoon / vessel. It is also
possible to move the crane on rails onto the pontoon / vessel if preferred utilising the
slewable bogies.
To achieve the loading/unloading the pontoon must able to ballast to the same level
as the quay. This procedure will be achieved using the trim function of the pontoon
and under the control of the supervision staff and a surveyor. After the successful
Roll On process the crane will be sea fastened with internal additional supports and
fastening steel tubes to the pontoon.
After the successful sea fastening the crane will be checked by an independent
authority such as Germanischer Lloyd, De Noske Veritas or similar.
The pontoon with the crane will be moved to the final port.
On arrival at the destination berth the crane will be unloaded in reverse of the loading
method. We will need 2-3 days before the crane can be moved onto the berth, due to
the removal and dismantling of the sea fastening.


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FEEDER SERVER® Standard

PROJECT NO: 27018/17

LOCATION: Hai Phong Dinh Vu / Vietnam

Customer: MIPEC Port

Document: FS Technical Description Standard Offer No.: 27018/17

1. MAIN PARAMETERS ........................................................................................................ 3

Document: FS Technical Description Standard Offer No.: 27018/17

1.1 TECHNICAL DATA

Document: FS Technical Description Standard Offer No.: 27018/17

 Main power supply to the crane

 Ambient climatic conditions

Document: FS Technical Description Standard Offer No.: 27018/17

Hoisting Trolley Gantry Boom

Document: FS Technical Description Standard Offer No.: 27018/17

The following inverter will be installed:

Manufacturer Siemens Series Sinamics S120 series

Drive system contains

control unit for control and regulation

SMART Line Bake unit Brake resistor

Document: FS Technical Description Standard Offer No.: 27018/17

 Applicable Standards and Regulations

Document: FS Technical Description Standard Offer No.: 27018/17

The design of the crane incorporates optimum operating practice, giving;

2.1 STRUCTURAL STEELWORK

For the welded steel structure (load- bearing

Steel: S355J2+N, S255J2 or equivalent (e.g. JIS,

The structural steelwork will be mainly of welded

 Bogies, Portal, Pylon

2.1.2 Bridge Girder

Document: FS Technical Description Standard Offer No.: 27018/17

Hydraulic buffer end-stops for trolley travelling will be fitted.

The WS boom is a lightweight box girder

Hydraulic buffer end-stops for trolley

The crane will be equipped with a self-

The trolley wheels run on the surface

The operator's cabin is a separate unit

Self-propelled Trolley running beneath the mono-box girder

Document: FS Technical Description Standard Offer No.: 27018/17

The electrical equipment is safely installed in cubicles located in a separate

A smoke detection system and fire extinguishers will be installed.

2.1.6 Stairs, Ladders, Platforms and Walkways

Stairways, ladders and walkways will be provided in sufficient numbers designed in

Document: FS Technical Description Standard Offer No.: 27018/17

The following painting schemes will be applied to the crane:

2.2.1 Exterior surfaces

De-rusting of the steel components according to SA 2½

 1 coat of primer on a 2-component epoxy zinc phosphate basis, DFT 70µm

2.2.2 Interior Surfaces

Non-accessible internal surfaces will be seal-welded only.

2.2.3 Access Structures

Components supplied by sub-contractors will be painted for outdoor use, compliant

Repair of transport and assembly damages will be carried out at site.

Document: FS Technical Description Standard Offer No.: 27018/17

2.3.1 Anti-friction Bearings

 Main hoist: disk brake and hydraulic safety brake.

Selection in accordance with FEM standards.

2.3.3 Crane Travelling Wheels

Wheel parameters will be selected in accordance with FEM standards.

2.4 MAIN HOIST MECHANISM

The main hoist mechanism will be

Main Hoist Mechanism on the LS Bridge Girder

Document: FS Technical Description Standard Offer No.: 27018/17

Main Hoist Rope Reeving Scheme (similar)