Overcoming Corrosion Challenges in Industrial Crane Systems: A Case Study
We recently received a call from an electrician at a major semiconductor manufacturer in Texas. Their facility, which produces silicon wafers and chips for the automotive industry, was facing significant challenges with their overhead crane system. This case study highlights the problems they encountered and our recommended solutions.
The Problem:
The facility's industrial waste area houses two 30-year-old overhead maintenance cranes, each spanning about 100 feet. These 30-40 amp cranes, likely 5-10 ton capacity, are crucial for lifting pump meters in a highly corrosive environment filled with acids and solvents.
Key issues included:
Severe corrosion of the bus bar system
Inconsistent voltage readings
Risk of motor burnout due to single phasing
Difficulty accessing the cranes for maintenance
Our Analysis:
Upon discussing the situation with the client, we identified that the existing bus bar system, likely galvanized steel, had deteriorated significantly over three decades of exposure to corrosive elements. The once-orange tracks were now rust-colored, indicating severe oxidation.
The Proposed Solution:
After careful consideration, we suggest a two-pronged approach:
Replacement Options:
a) Standard Bus Bar System: A cost-effective solution that would require more frequent replacements.
b) Volley Bus Bar System with Sealing Strip: A more durable option featuring copper components and a protective flap, similar to what's used in galvanizing facilities.Accessibility Plan:
Conduct an on-site assessment to determine the best method for accessing the cranes, potentially using an 80-foot man lift or scaffolding.
Our Recommendation:
Given the corrosive environment, we lean towards recommending the Volley Bus Bar System. While initially more expensive, its longevity and resistance to corrosion make it a cost-effective choice in the long run. This system is widely used in similar industrial settings and has proven its worth in harsh conditions.
Next Steps:
We've offered to send our experienced technicians to conduct an on-site evaluation. This will allow us to:
Discover more about the crane amperage and capacity
Assess the full extent of the damage
Determine the best access method for repairs
Provide a detailed quote for both standard and Volley bus bar options
We understand that each industrial setting presents unique challenges. Our goal is to provide tailored solutions that not only solve immediate problems but also offer long-term reliability and safety for our clients' operations.
Stay tuned for updates on this project, and don't hesitate to contact us if you're facing similar challenges in your facility. We're here to lift your business to new heights!