of the requirement for the Bachelor of

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Effect of Energy Recovery on the Hoisting Crane Adapting Closed Loop Hydraulic Hoisting System

by

Ahmad Hasnulnaim Bin Che Kamaruddin

Dissertation submitted in partial fulfillment of the requirement for the

Bachelor of Engineering (Hons) (Mechanical Engineering)

SEPTEMBER 2011

Universiti Teknologi PETRONAS Bandar Seri Iskandar

31750 Tronoh Perak Darul

Ridzuan

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CERTIFICATION OF APPROVAL

Effect of Energy Recovery on the Hoisting Crane Adapting Closed Loop Hydraulic Hoisting System

Approved by,

by

Ahmad Hasnulnaim Bin Chc Kamaruddin

A project dissertation submitted to the Mechanical Engineering Programme

Universiti Teknologi PETRONAS In partial fulfillment of the requirement for the

BACHELOR OF ENGINEERING (Hons) (MECHANICAL ENGINEERING)

(Prof. Dr. Nagarajan Thirumalaiswamy)

UNIVERSITI TEKNOLOGI PETRONAS TRONOH, PERAK

September 2011

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CERTIFICATION OF ORIGINALITY

This is to certify that I am responsible for the work submitted in this project, that the original work is my own except as specified in the references and acknowledgements, and that the original work contained herein have not been undertaken or done by unspecified sources or persons.

AHMAD HASNULNAIM BIN CHE KAMARUDDIN

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ABSTRACT

The purpose of this project is to research and study the effect of energy recovery from closed loop hydraulic hoisting system. The project is specifically involving various types of hoisting cranes such as tower cranes, crawler cranes and offshore cranes. In some cases, closed loop hydraulic hoisting circuit is said to have pump 'back driving' during lowering the load. The winch is the spool of the crane and its function is to adjust the tension of the wire rope, on in the case of lowering load, to let out the tension of wire rope so the load will be lowered. But, when the load is of sufficient weight, the hydraulic motor at the winch will behave like a hydraulic pump instead of pushing flow back to the actual hydraulic pump. This phenomenon is what needed to be study and find if there will be some effect to the prime mover (for example diesel motor and electric motor). However, the solution for this problem is said to be introducing a heat loading in the system. Heat loading means is to maintain a power resistance so that there will be a countering effect equivalent to the lowering power generated by the hydraulic motor at the winch. Energy recovery methods are essential so that crane system can recover and reutilize energy, save pump supply energy and improve energy utilization of the crane system. To conduct this project, a method of using the assistant systems and ELS system will be used to recover the energy that was wasted during the crane operation. Thus, the effect on the equipments that are involved in inducing back driving phenomenon will be determine.

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ACKNOWLEDGEMENTS

The author wishes to take the opportunity to express utmost gratitude to Allah the Almighty upon the completion of this Final Year Project. Without His love and mercy, it is impossible to do anything related to this project.

A special thanks to respectable supervisor, Prof. Dr. Nagarajan Thirumalaiswamy for the opportunity given to the author to accomplish this project under his supervision.

Also the same greeting goes to Dr. Tadimalla Varaha Venkata Lakshmi Narasimha

Rao,

as co - supervisor for this project. Attention, patience and knowledge shared by them had been really helpful in ensuring a steady progress of this project.

A very special thanks goes to the Final Year Project Coordinator, Dr. Mohd Faizairi bin Mohd Nor for providing the author with all initial information required to perform the project.

Not to be forgotten, the author also want to express his gratitude towards the technicians in Mechanical Engineering department,

Mr

lrwan bin Othman,

Mr

Mohd Shairul bin Harun,

Mr

Jani bin Alang

Alunad

and

Mr

Shaiful Hisham bin Samsudin for assisting the author in using the required laboratory facilities.

Last but not least, a very deepest thanks to family and friends for their love and support to the author throughout this project.

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TABLE OF CONTENTS

TABLE OF CONTENTS ... 2

ABSTRACT. ... 3

LIST OF FIGURES ... .4

1.0 INTRODUCTION ... 5

1.1 Background of Study ... 5

1.2 Problem Statement ... 6

1.2.1 Problem Identification ... 6

1.2.2 Significance ofProject ... 6

1.3 Objective and Scope ofthe Project.. ... 6

1.3.1 Objectives ... 6

1.3.2 Scope of the Project ... 7

1.4 Relevancy ofProject ... 7

2.0 THEORY & LITERATURE REVIEW ... 8

3.0 METHODOLOGY ... 17

4.0 RESULT AND DISCUSSION ... 26

5.0 CONCLUSION ... 39

6.0 RECOMMENDATION ... 39

REFERENCE ... .40

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