This is a good example of why you shall avoid being in the danger zone of a heavy load, and if you need to be close to it you shall still make sure that you don't get trapped if things goes wrong.
Amazing to finally see a crane accident vid that wasn't user error! Cranes are marvelous machines, but this proves that anything can happen at ANY time!! As already mentioned, never put yourself UNDER a load. Man. this is sobering.
I received my apprenticeship through Siemens working on steam turbines. one of first things I was taught...never ever stand under a part or between a part and a wall. saw lots of huge parts. not having a lot of confidence and machining/transferring large parts don't go well together.
I can translate if you like, @ 1:04 the guy is saying "Hey Hans, wait till the boss finds out how much money we saved by getting the new slings off that Ebay guy in China...."
There is usually a sheet metal tube like safety device that just clamps around the coupling, to prevent the coupling from falling apart like this one. Even when it breaks up like this, the sheet metal housing will keep the broken parts of the coupling closely in place and prevent them falling apart like this and prevent disaster. I wonder why this was not place ?
used a Lovejoy coupling on a crane?I've seen hydraulic systems tear those apart. the cranes I've worked on ( acco and Robbins and Myers) use a splined coupling between the motor and gearbox.they lost their brake when the coupling failed.
Perhaps the new standard before crane moving something of that weight and value, subjecting critical crane components like that shock coupling to magnafluxing be advised?
This is the reason why you NEVER put yourself below any slung weight, the guys aren't even guiding it, they are milling about for no reason. So lucky the failure wasn't earlier or from a higher position. Glad no one was hurt and everyone involve will learn a good lesson.
A hoist requires 2 methods for controlling the lowering of the load, regardless of capacity. The exception being hot metal carries, which require a load brake. The hoist motor is accepted as a second method of controlling the load. Other methods include Eddy Current Braking Thyristor Drive Pole Changing Motor Statiic Stepless, VFD's with feedback, I've even seen Foot Brakes w/ cab cranes. I believe you can find this in CMAA specification 70. "Vector " drive is a great option, but not required.
Like many others have said, what the hell were those clowns doing under a suspended load. I worked in cranes and rigging for a few years and if there is one thing you learn on the first day it's don't be under or near a suspended load.
Were the causative factors for this load drop formally announced? Appears to be fatigue crack initiation line along outboard edge of the brake-wheel coupling. And note the input shaft to the gearbox is completely gone. Any idea of the coupling manufacturer?
@dishortt1 Yeah I'm pretty sure you are right. I dont remeber a 7fa having a center bearing. Could be a 7fe at least I think thats what we tore apart in birch bay. It had a center bearing. Hard to tell without getting a closer look at the case.
I'm no rigging expert and maybe I'm missing something, but that broken metal pully/coupling assembly looks to be severely undersized for the load that was on it. It also looks to be made out of crap "steel", the metals grain size looks large for its intended application.
Good thing that rotor was there to catch the spreader beam lol... I'm guessing the two guys close by had to change their shorts before inspecting the damage
2:20 that guy was literally seconds away from becoming a human pancake.. With no operational crane you wouldn't be able to get him out even if he survived..
The friction brake has to function to bring the hoist to a standstill. Even with DC injection braking you can't brake an induction motor to a standstill, there will always be slip.
Operator error....looks like maximum load and he was jogging down in high speed and allowing the brake to pull it up. You'll overheat the brake and it will crack (which is what happened). Should have just lowered in a slow speed which is what the crane was capable of judging by the amount of rope drops on the hook. It takes longer but not as long as doing the job twice. Think I'm wrong? Car 4x4 manufactures have Hill descent control to prevent perfectly good brakes failing for the same principle.
Here is a good reason for workers never stand under a hanging load. Im working in a paper mill with several cranes over 50t recently during an new steam turbine instalation an 45t crane with only 5 years got replaced for a brand new one also 45t. Just to be sure that it would stand the load its much cheaper a new crane than stop energy production for a very long time these turbines arent cheap and they cant be found in stock any were to be replaced in a few days.
That lovejoy didn't fail and cause the accident, the damaged lovejoy is part of the carnage that happened when the brake failed and the hoist ran away. For whatever reason that it ran away, it looks like it over-sped so much that the brake drum exploded from centrifugal force and took the rest of the drive with it. And remember, an AC induction motor can not brake an overhauling load down to zero RPM, No matter how low you set the frequency of the drive (synchronous speed). Friction has to work
It's such a 1000 times said common knowledge that people shouldn't walk underneath crane loads. But even at my own work I see people doing stuff underneath 2000kg metal blocks which are on a hoist. Seems like people need to experience a (probably fatal) failure themselves before getting the point.
Good Day, Oh boy,..that was very close call for the guidemen! Happy they survived this. It was about 5 million USD loss in the blade assy alone, never mind reworking the lower case,..not to mention the ruined crane. Fractured casting. It looked to me it was being lowered too fast. I mean before failure. It appeared to be 10cm decent, stop,..10cm drop. It (crane) may have been past due for overhaul. A "magging" would have revealed the hairline crack, saving the accident from happening..
Okay so some have been argueing about if this is a steam or a gas turbine. Firstly, let's assume that the uploader knows what he's talking about. Secondly, also steam turbines can have "combustion stages" which are to compensate the loss of the steam's volume, due to temperature reduction. Beside that, you can see the opposite blades in the stator, which are there to steer the steam jet onto the rotor blades in a stumper angle (increses efficiency). Very typical for steam turbines.
These guys look like the're all seasoned pros ----- but still complacency takes over. The crane is obviously at the limit of it's capacity --- but the guys are just milling about just about the crush zone. No one ever learns --- ever .
yes, it's a gas turbine for electrical generation. We can see it because there are two parts : the compression part with 16 stages (1:33) and the turbine with 3 stages (1:36) ^^
They should have training for people who will operate around these loads ...picking heavy loads up and dropping them on catchup filled ballistic gel dummies. Same with fork lifts. Any load. Even a cable snap will crush you.
At 3:42 they are shining a light at a space immediately adjacent to where there is an industrial electric motor. At 3:44 - 4:06 they are focused on a failed casting. Looks like a gear reduction assembly failed.
This is a good example of why you shall avoid being in the danger zone of a heavy load, and if you need to be close to it you shall still make sure that you don't get trapped if things goes wrong.
Do you still alive ?
Amazing to finally see a crane accident vid that wasn't user error! Cranes are marvelous machines, but this proves that anything can happen at ANY time!! As already mentioned, never put yourself UNDER a load. Man. this is sobering.
From an engineers stand point this video is heart breaking.
I agree 100% there is no situation where anyone should stand under a load.
Well, the good news is, we got yer turbine in quicker than expected!
That was sick humor lol
I received my apprenticeship through Siemens working on steam turbines. one of first things I was taught...never ever stand under a part or between a part and a wall. saw lots of huge parts. not having a lot of confidence and machining/transferring large parts don't go well together.
Fell right into place, like a boss. Now put the top on and let's get outahere.
you must be a millwright
@@steverosema4026 .JB WELD or us flex tape.
Must have taken a very long time to machine that turbine shaft...destroyed in seconds
Ebay: One Turbine. Never Used. Slight Cosmetic Damage. Cheap!!
Steve Rogers buyer collects
That's what you get when you're working on machines running close to their full capacity.
I can translate if you like, @ 1:04 the guy is saying "Hey Hans, wait till the boss finds out how much money we saved by getting the new slings off that Ebay guy in China...."
it wasn´t the sling. You can hear the gear sound when the gear wheel looses it´s teeth.
That was a near death moment... and it also looked really expensive.
if they didnt totally destroy the shaft and bearing surfaces. all the turbine blades are completely replaceable individually.
Nice to know the source was a DVD!
There is usually a sheet metal tube like safety device that just clamps around the coupling, to prevent the coupling from falling apart like this one. Even when it breaks up like this, the sheet metal housing will keep the broken parts of the coupling closely in place and prevent them falling apart like this and prevent disaster. I wonder why this was not place ?
used a Lovejoy coupling on a crane?I've seen hydraulic systems tear those apart. the cranes I've worked on ( acco and Robbins and Myers) use a splined coupling between the motor and gearbox.they lost their brake when the coupling failed.
Luckily, the turbine blades bent and saved the yellow bar from being damaged.
I glad you clarify it for me, for I know the 3 stages are the supersonic stages and the first 16 are the transonic stages
That yellow crane component fits nicely with blades. Good job!
I would not want to be the foreman that had to explain this one to the boss.
Perhaps the new standard before crane moving something of that weight and value, subjecting critical crane components like that shock coupling to magnafluxing be advised?
and some blades damaged, in conclusion it needs to be build again...
Hoist brake failure or winch gearbox....never go under load!
This is the reason why you NEVER put yourself below any slung weight, the guys aren't even guiding it, they are milling about for no reason. So lucky the failure wasn't earlier or from a higher position. Glad no one was hurt and everyone involve will learn a good lesson.
And thats why you never walk under a suspended load
A hoist requires 2 methods for controlling the lowering of the load, regardless of capacity. The exception being hot metal carries, which require a load brake. The hoist motor is accepted as a second method of controlling the load. Other methods include Eddy Current Braking Thyristor Drive Pole Changing Motor Statiic Stepless, VFD's with feedback, I've even seen Foot Brakes w/ cab cranes. I believe you can find this in CMAA specification 70. "Vector " drive is a great option, but not required.
Ok but what failed the crane clutch or brake ???
This power turbine damage is going to cost millions!!!
Like many others have said, what the hell were those clowns doing under a suspended load. I worked in cranes and rigging for a few years and if there is one thing you learn on the first day it's don't be under or near a suspended load.
In a repair it was reported to me that an inferior coupling was used between the rope drum and gear box.
The Fluxcapicitor was out of sync.
Were the causative factors for this load drop formally announced? Appears to be fatigue crack initiation line along outboard edge of the brake-wheel coupling. And note the input shaft to the gearbox is completely gone. Any idea of the coupling manufacturer?
And now the phone call you never want to make .
"Hey Mike, pass me the Bondo please."
That cast casing looks like it has ‘older’ cracks on the outside. The break showed old and brand new exposed surfaces.
They nearly had it in place too. That was a close call for the two men standing next to it.
"Liiiike a glove"!!!!!!!!
Can just hear ace Ventura saying that lol
@dishortt1 Yeah I'm pretty sure you are right. I dont remeber a 7fa having a center bearing. Could be a 7fe at least I think thats what we tore apart in birch bay. It had a center bearing. Hard to tell without getting a closer look at the case.
"Well bob, looks like we're getting overtime this weekend."
Crazy I see this lift quite often. And everyone wonders why I don't want to be anywhere near it when its going on!
I'm no rigging expert and maybe I'm missing something, but that broken metal pully/coupling assembly looks to be severely undersized for the load that was on it. It also looks to be made out of crap "steel", the metals grain size looks large for its intended application.
Were the journals damaged?
Isn't that a person trapped/pinned (left side) at 2.42 onwards?
Good thing that rotor was there to catch the spreader beam lol... I'm guessing the two guys close by had to change their shorts before inspecting the damage
Yikes that is an expensive boobo! I used to build turbines, and they are not cheap nor quick to fix!!
But is in.:)What did they do after?repair?
2:20 that guy was literally seconds away from becoming a human pancake..
With no operational crane you wouldn't be able to get him out even if he survived..
No lord to thank, just nice timing.
Clutch before you shift or you grind the gears. I learned that in my old '48 Plymouth at 16.
Never stand under the load. Ever.
Dudes that's a bummer man
@502c10 i heard that too..mabee not enough parts of line
Thats a gas turbine rotor not a steam turbine. But great video. I will be thinking of it next time I'm lifting one.
well that looks expensive!
Must have been near lunch time, seems a bit hasty closing up that last bit of gap.
lol
The friction brake has to function to bring the hoist to a standstill. Even with DC injection braking you can't brake an induction motor to a standstill, there will always be slip.
Operator error....looks like maximum load and he was jogging down in high speed and allowing the brake to pull it up. You'll overheat the brake and it will crack (which is what happened). Should have just lowered in a slow speed which is what the crane was capable of judging by the amount of rope drops on the hook. It takes longer but not as long as doing the job twice. Think I'm wrong? Car 4x4 manufactures have Hill descent control to prevent perfectly good brakes failing for the same principle.
Does anyone inspect their machinery?
How many millions gone?
Did they know the weight and maximum load of the crane?
Wonder if that voided the warranty???
Here is a good reason for workers never stand under a hanging load.
Im working in a paper mill with several cranes over 50t recently during an new steam turbine instalation an 45t crane with only 5 years got replaced for a brand new one also 45t.
Just to be sure that it would stand the load its much cheaper a new crane than stop energy production for a very long time these turbines arent cheap and they cant be found in stock any were to be replaced in a few days.
that turbine looks expensive.
That lovejoy didn't fail and cause the accident, the damaged lovejoy is part of the carnage that happened when the brake failed and the hoist ran away. For whatever reason that it ran away, it looks like it over-sped so much that the brake drum exploded from centrifugal force and took the rest of the drive with it. And remember, an AC induction motor can not brake an overhauling load down to zero RPM, No matter how low you set the frequency of the drive (synchronous speed). Friction has to work
Holy crap that looked expensive
My guess would be 20 million.
Looks like someone was looking up MacDonald drive through jobs after this rough landing
It's such a 1000 times said common knowledge that people shouldn't walk underneath crane loads. But even at my own work I see people doing stuff underneath 2000kg metal blocks which are on a hoist. Seems like people need to experience a (probably fatal) failure themselves before getting the point.
That'll buff right out!
I think I'll just grab my toolbox and leave now !
The sound when billions of dollars hit the ground
Nothing a hammer and some duct tape can't fix.
+specwar64
Correct!
specwar64 don't forget cable ties the solution and the problem at every workplace
Good Day,
Oh boy,..that was very close call for the guidemen!
Happy they survived this. It was about 5 million USD loss in the blade assy alone, never mind reworking the lower case,..not to mention the ruined crane. Fractured casting. It looked to me it was being lowered too fast. I mean before failure. It appeared to be 10cm decent, stop,..10cm drop. It (crane) may have been past due for overhaul. A "magging" would have revealed the hairline crack, saving the accident from happening..
that is one expensive gas turbine
You right, it is a steam turbine...I was looking at the blades wrong
at 0:57, i like the duct that goes around the beam. someone didnt plan that well.
Okay so some have been argueing about if this is a steam or a gas turbine. Firstly, let's assume that the uploader knows what he's talking about. Secondly, also steam turbines can have "combustion stages" which are to compensate the loss of the steam's volume, due to temperature reduction. Beside that, you can see the opposite blades in the stator, which are there to steer the steam jet onto the rotor blades in a stumper angle (increses efficiency). Very typical for steam turbines.
If that damaged the casing and bearings they are really screwed. Wonder who is going to pay for that..?
never go in underneath the crane you will get trapped underneath a Crane..
well there goes that turbine ouch
You're FIRED!!
These guys look like the're all seasoned pros ----- but still complacency takes over.
The crane is obviously at the limit of it's capacity --- but the guys are just milling about just about the crush zone.
No one ever learns --- ever .
Now THAT'S Jenga!
Like a glove!
That was very expensive.
NOT FLAT IMPALLED
well that turbine came down for sure....
That's where aircraft turbines are great - just swap the bent blades and the opposing ones for new balanced pairs, and you're good to go!
IT'S IN !!! LUNCH TIME !!!
yes, it's a gas turbine for electrical generation. We can see it because there are two parts : the compression part with 16 stages (1:33) and the turbine with 3 stages (1:36) ^^
Why the hell would you be under a load
its a gas made up of water vapour... if its not liquid or a solid ...what is it?
ijsselcentrale ?
....Like a glove!!!!
now they gotta wait another year, for a replacement.!
sue the crane maker.!
2nd birthday for the two working men!
ist a boat gas turbine????
Well, it's in place.. Harder than usual, but its there.
They should have training for people who will operate around these loads ...picking heavy loads up and dropping them on catchup filled ballistic gel dummies. Same with fork lifts. Any load. Even a cable snap will crush you.
I think its fine.
I agree!
At 3:42 they are shining a light at a space immediately adjacent to where there is an industrial electric motor. At 3:44 - 4:06 they are focused on a failed casting. Looks like a gear reduction assembly failed.
At 2:25 a workman is working around the Turbine during it`s down....10 second after....crash....definitively Re-born
A HELL'VA LOT OF PAPERWORK!!
3:20 alright boys, let's all take a 5 for some underpants change. .......👍🏼
Thats how you set in a rotor great job guys