• Apr 11, 2022
• Case Studies

45 Ton Specail Designed Electric Hoist for Philippines

Yuantai Crane provided a custom 45-ton electric hoist solution for a Philippine client to lift a 50-ton boiler steam drum 30 meters high with minimal movement.

The customer is a leading boiler fabrication and installation contractor in the Philippines. Their work involves supplying and installing large industrial boilers for power plants, manufacturing facilities, and large-scale heating systems. In this sector, handling and positioning heavy, cylindrical components—such as steam drums—are critical steps in the boiler‐erection process. Ensuring precise, safe, and stable lifting is essential to maintain schedules, avoid costly rework, and protect worker safety.

Client Requirements

The customer was working on a large boiler project and needed a customized material handling solution to lift a pressure vessel ladle approximately 14 meters long and weighing approximately 50 tons. According to the customer, they needed to lift the boiler package from the ground to the ceiling beams, which were double truss beams with a distance of only 5 meters wide between the truss beams. The steam bag must be lifted from the ground to the double truss top beam 30 meters above the ground. Key requirements include:

• High Lifting Capacity: Safely lift loads up to 50 metric tons, with safety margins. The client chose two 45T units rather than 30T hoists for additional buffer.
• Vertical Lift Height: Achieve a lifting height of 30 meters to reach the truss beams that support the boiler structure.
• Minimal Horizontal Movement: Restrict lateral load travel, as the steam drum needed only slight repositioning once suspended.
• Stable Load Control: Maintain load stability through the entire lift to avoid oscillations or collisions with surrounding structural elements.
• Robust Structural Support: Integrate hoists with custom H-beams spanning the 5-meter distance between truss supports. Each H-beam had to bear half the load, with a bottom flange thickness of 40 mm and a top plate of 26 mm.

Challenges Before Adopting Yuantai's Hoisting Solution

1. Inadequate Lifting Equipment

Before contacting Yuantai, the customer attempted to use their existing crane and chain block setup. This system lacked the capacity and safety features to handle a 50-ton, 14-meter steam drum. Attempts to lift with smaller hoists risked structural damage and unsafe load conditions.

2. Limited Overhead Support

The installation site featured double-truss steel beams with only a 5-meter span between them. Traditional cranes and gantry solutions could not be rigged between the trusses, and their floor-mounted gantries could not reach the required 30 m height.

3. Safety and Stability Concerns

Lifting such a long, heavy drum through 30 m of vertical space required a highly stable, synchronized dual-hoist setup. Any misalignment or unsynchronized hoisting could lead to oscillations, causing potential collisions with the supporting trusses or damage to the drum.

Yuantai's Customized Solution

Yuantai's engineering team designed a specialized lifting system using two 45-ton electric wire rope hoists mounted on custom H-beams. This arrangement provided the necessary capacity, stability, and vertical reach for the 50-ton steam drum. Key design elements included:

Custom H-Beam Support Structure

• Two H-beams sized H800×W300 mm, with a 40 mm bottom plate and 26 mm top plate.
• H-beams positioned on either side of the 5 m-wide truss gap, ensuring each hoist carried approximately 25 tons during the lift (50 tons total).
• Reinforced welding and gusset plates to guarantee rigidity and prevent deflection under load.

45T Electric Wire Rope Hoists

• Rated Lifting Capacity: 45 metric tons per hoist, providing a safety margin beyond the required 25 ton-per-hoist load.
• Lifting Height: 30 meters, meeting the vertical clearance needs to reach the truss beams.
• Synchronization Capability: Both hoists electrically synchronized to lift the drum in unison, preventing twisting or uneven lifting.
• Dual-Speed Control: Slow speed for precise positioning during the final lift phases and faster speed for initial vertical travel.
• Safety Devices: Overload limiter, upper and lower limit switches, emergency stop functions, and a mechanical brake system to hold load securely under power loss.

Hoist Integration and Installation

Proper hoist integration is essential for ensuring long-term performance and operational safety, and the installation of the two 45-ton electric hoists was carried out through a series of carefully planned steps. At Yuantai's factory, both hoists were fully assembled with motors, drums, gearboxes, and control units, and each unit underwent a rigorous load test at 125% of rated capacity to verify structural integrity, brake function, and lifting precision. For safe international transport to Manila, the hoists were securely packaged in reinforced plywood crates with internal supports and moisture-resistant linings to protect against shock and corrosion during sea shipment. Upon arrival, Yuantai's field engineers provided expert on-site support, including precise beam alignment, hoist mounting, and trolley rail adjustments using laser instruments to ensure perfect level and straightness across the crane span. The final commissioning phase involved completing all electrical connections, testing safety systems, and performing supervised full-capacity load tests to confirm synchronized hoist operation. Functional checks of travel, braking, and emergency stop systems verified that all performance and safety standards were fully met.

Advantages of Yuantai's Electric Hoist Solution

Yuantai's dual 45 ton electric hoist setup offers a blend of capacity, precision, and safety tailored for heavy lifts. Here are the key benefits:

1. High Load Capacity with Safety Margin

By pairing two 45 ton hoists for a 50 ton steam drum, each unit operates well below its maximum rating. This load sharing reduces mechanical stress on gears and ropes. The result is lower wear rates and improved long-term reliability for high-demand lifting cycles.

2. Precise Dual-Hoist Synchronization

A dedicated control system keeps both hoists lifting in perfect unison. Throughout the 30 m travel, the steam drum stays level and free of swing. This prevents binding or contact with overhead truss members and reduces the risk of damage to both load and structure.

3. Simplified Structural Requirements

Rather than erecting a full gantry, engineers mounted a custom H-beam support directly to existing truss members. This retrofit saved on civil works and cut installation time. It also avoided major modifications to the building's frame, minimizing disruption to ongoing operations.

4. Enhanced Safety Features

Each hoist includes overload protection, upper and lower limit switches, and an emergency-stop circuit. If power fails, mechanical brakes engage to hold the load securely. These safeguards give operators clear, reliable control over every lift.

5. Extended Service Life and Low Maintenance

Critical parts—such as heat-treated wire ropes, greased bearings, and reinforced gears—are designed for longevity. Routine upkeep requires only visual inspections and periodic rope lubrication. This maintenance regimen keeps downtime to a minimum and extends the hoists' operational life.

Performance and Adaptability in the Field

During the installation, Yuantai's electric hoists performed across challenging conditions:

• Heavy Vertical Lift (30 m): Hoists maintained stable, controlled movement over the full height without overheating or load drift.
• Constrained Workspace: The truss-mounted H-beams and hoists fit within existing structural confines, requiring only minimal workspace for beam placement.
• Minimal Horizontal Movement: Hoist trolleys locked in place to prevent lateral travel, matching the requirement of lifting without shifting the steam drum side-to-side.

Customer Feedback

Yuantai's 45-ton electric wire rope hoist system provided a robust, safe, and adaptable lifting solution for a critical boiler installation project. By addressing high capacity, vertical height, and structural constraints, our hoists delivered reliable performance under challenging conditions. This case highlights Yuantai's expertise in designing customized industrial lifting solutions that serve a variety of heavy-duty applications across industries.

Conclusion

Yuantai's 45-ton electric wire rope hoist system provided a robust, safe, and adaptable lifting solution for a critical boiler installation project. By addressing high capacity, vertical height, and structural constraints, our hoists delivered reliable performance under challenging conditions. This case highlights Yuantai's expertise in designing customized industrial lifting solutions that serve a variety of heavy-duty applications across industries.