Portfolio : Engineering, Industrial Automation

Upgrade Control of the 200 TON Crane

Client: Army Corps of Engineers
Location: Blakely Power Plant, Vicksburg District
Year: 2022

Scope of Work

Blakely Power Plant of the Army Corps of Engineers, Vicksburg District, requires reconditioning, reconfiguring, and upgrading the generator bay cyclops 200 ton overhead crane controls to a ground-controlled belly box system or by belly box radio control from the cab of the crane.


  • Removal of all motors on the crane (7) and have them reconditioned and reconfigured to operate properly with variable frequency drive (VFD) controls.
  • Remove bridge cross conductors mounted on the bridge and fabricate and install two festoon systems.
  • Installation of a new seven-function VFD panel to control all motions. These drives shall have the capability to be set up in two different formats: five distinct speed steps or two steps infinitely variable.

The new panel will include the following:

  • VFDs for all motions.
    • Mainline contactor.
    • Thru door disconnect.
    • A/B and A or B Logic Controls.
    • Under Voltage and Phase Loss Relays.
    • LED Work Lights in the Enclosure.
    • Radio/Pendant Transfer Switch with Isolation Relay.
    • All components will be labeled and tagged.
    • The main hoist shall be configured for A/B and A or B control.
  • Installation of radio controls with belly box-style transmitter. The transmitter will have A/B and A or B controls where the approximate range of the transmitter must be 300′ line of sight. The external receiver will be antenna type. The transmitter will be standard with NIMH batteries with battery status and charge. Spare transmitter included.
  • Remove the existing parking brake and install a 12″ diameter thruster type brake with automatic adjustment. This brake will serve as a parking and service brake. The existing hydraulic service brake will be removed.
  • Complete functional test of all movements once the installation is complete.
  • When the project is complete, the crane will have all motions operated by Variable Frequency Drives. The crane will be controlled by a belly box radio control system on the ground or by belly box radio control from the cab of the crane. There will not be any stationary controllers in the cab of the crane.
  • Mandatory Weight load test once the upgrade is complete.
  • Provide and install a new 150′ Conductor Bar

Motors to be removed, reconditioned, and reconfigured for VFD controls:

  • Bridge – Frame 444 x 1
  • 30 HP
  • 875 RPM
  • 440 Volt 3 Phase
  • 60 Cycle
  • Trolley – Frame 324 x 2
  • 5 HP
  • 860 RPM
  • 440 Volt 3 Phase
  • 60 Cycle
  • Aux. Hoist – Frame 504 x 2
  • 50 HP
  • 865 RPM
  • 440 Volt 3 Phase
  • 60 Cycle
  • Drip-Proof
  • Main Hoist – Frame 445 x 2
  • 40 HP
  • 875 RPM
  • 440 Volt 3 Phase
  • 60 Cycle

Documentation Required:

The contractor shall provide the following documentation to Blakely Power Plant:

  • Electrical drawings/documentation to support installation of new equipment.
  • Specifications.
  • Operation and Maintenance Manuals.
  • Updated parts listing.
  • All equipment warranty paperwork.

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