INTERPLANT STANDARD – STEEL INDUSTRY

SPECIFICATION FOR HORIZONTAL GEAR

BOXES FOR CRANES IPSS:1-08-014-18
(Second Revision)

Corresponding IS does not exist Formerly:

IPSS:1-08-014-14
(First Revision)

0. FOREWORD

0.1 This Interplant Standard has been prepared by the Standards Committee on Lifting and
Hoisting Equipment, IPSS 1:8 with the active participation of the representatives of all
the steel plants, established manufacturers of crane hooks and leading consultants and
was first adopted in March, 1997. Thereafter standard was first revised in January
2014 and This Standard discussed again in presence of experts from SAIL, RINL,
TATA STEEL, ESSAR, JSPL and Consultants of MECON, HEC & DASTURCO and
revised with second revision in August, 2018.

0.2 Interplant Standards for steel industry primarily aim at achieving rationalization and
unification of parts and assemblies used in steel plant equipment and provide guidance
in indenting stores for existing equipment (or while placing orders for additional
requirements) by individual steel plants. For exercising effective control on inventories,
it is advisable to select a fewer number of sizes/ types from those mentioned in this
standard. These limited sizes/ types can be adopted as Plant Standards for an
individual steel plant. It is not desirable to make deviations in technical requirements.

1. SCOPE

1.1 This Interplant Standard covers the requirements of Two stage horizontal helical / spur
gear boxes used for the different motions of EOT Cranes.

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1.2 Any requirement not mentioned in this standard shall be as per IS 4137:1985 `Code of
practice for heavy duty EOT cranes including special service machines for use in steel
works (first revision)’ for steel duty cranes and IS:3177:1999 `Code of practice for EOT
cranes and gantry cranes other than steel work cranes (first revision)’ for General
Purpose Cranes.

2. DIMENSIONS

2.1 Dimensions of Two stage horizontal gearboxes shall be as given in Table-1 (to be
read with Fig-1).

3. kW RATING

3.1 The kW rating of the Two stage horizontal gear boxes shall be as given in Table-
2A, 2B & 2C used for different duty classes of the cranes.

4. CONSTRUCTION

4.1 The gearbox housings shall be made of cast steel grade 280-520 W, IS 1030:1998
`Carbon steel castings for general engineering purposes’ and annealed or of
fabricated construction out of structural steel as per IS 2062:2011 `Steel for general
structural purposes ’ and stress relieved. Minimum thickness of plate should be 8 mm.
Gear and shaft materials shall be selected as per design requirement. Small cover at
input stage shall be preferred.

4.1.1 The gearbox shall have at least two lifting lugs / eye bolts on each of the upper
housing and the lower housing suitably located for handling.

4.1.2 Breathers, oil level indicator with min / max marking, drain out plugs and dowel pins
shall be provided at conveniently accessible locations.

4.1.3 Oil tight inspection covers shall be provided near the mesh lines with perpendicular
flats welded on the inner surface to avoid oil splashing and leakage. Inspection covers
shall also be provided for inspection of ratchet assembly. Inspection covers shall have
bolts with flynuts.

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4.1.4 The joints of the housings shall be oil tight, dust proof and water proof suitable for
outdoor duty. Lower flanges shall have grooves cut in them and these grooves shall
be connected back to the inside of the housing. Oil deflector shall be provided on top
cover to eliminate oil leakage.

4.2 Bearings - Antifriction bearings based on duty requirement shall be used.

4.3 Oil Seals – Suitable oil seals as per IPSS:1-02-013-81 specification for rotary shaft oil
seal units shall be provided.

5. DESIGN REQUIREMENTS

5.1 Direction of Rotation – All gearboxes shall be capable of working in either direction.

5.2 Type of Assembly – Type of assembly shall be selected from Fig-2.

5.3 Shaft Ends – Shaft ends shall be selected from Fig-3.

5.4 The keys and keyways shall be as per IS 2048:1983.

5.5 Special requirement, if any, shall be specified by the Purchase while ordering.

5.6 This standard specifies the overall dimensions, kW rating and other details of gearbox.
Material specification, hardness, backlash, etc of internal components shall be as
agreed to between the purchaser and the supplier.

6. LUBRICATION

6.1 Lubrication for gears and bearings shall be such that the temperature of lubricating oil
does not exceed 25degree C over the ambient temperature. In case grease is used for
lubricating the bearings, provisions shall be made to avoid mixing of grease with oil.

7. SELECTION OF GEAR BOXES

7.1 The gear boxes shall be selected in line with the method laid down in
IPSS:1-01-024-86 (Code of Practice for selection of Gear Box).
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8. DESIGNATION OF GEAR BOXES

8.1 A gearbox shall be designated by the following:

a) Type As per Table-1

b) Type of Assembly As per Fig-2

c) Shaft Endings As per Fig-3

d) Nominal Ratio As per Table-2A, 2B & 2C

e) Standard No. IPSS:1-08-014-97

Example: A Two stage horizontal gearbox of 750 mm centre distance (Type DHR-750)
with nominal ratio 20:1, assembly type 4B as shown in Fig-2 with input shaft
end of type 1A and output shaft end of OD shall be designated as:

Type Assembly Type Input Shaft end Output Shaft end Nominal Ratio IPSS NO.
DHR- 750 4B IA OD 20 IPSS NO.
1-08-014-

9. MARKINGS

9.1 Every gearbox shall have a name plate indelibly marked with the following information:

i) Manufacturer’s name, trade mark, year of manufacture and serial number

ii) Designation of gearbox
iii) kW rating and input rpm

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iv) Weight of gear box in kg

10. Inspection of gearboxes shall be carried out as laid down in

IPSS:1-08-020-94 (Acceptance Norms for Crane Gear Box).

11. TECHNICAL INFORMATION

11.1 Every gearbox shall be accompanied with a maintenance manual containing the
following:

i) Specification and quantity of lubricant

ii) Designation of bearings and oil seals used
iii) (GD * GD) value
iv) Maximum permissible overhung load for input and output shafts
v) General arrangement drawing

11.2 Detailed drawings of all the internal components shall be supplied.

12. PAINTING

12.1 Painting shall be as follows:

i) Gear boxes shall have minimum one coat of suitable primer (inside and
outside)

ii) Inside surfaces shall be painted with minimum two coats of oil resistant paint

iii) Outside surface shall be painted with minimum two coats of anti-corrosive paint

13. GUARANTEE

13.1 The gearbox shall be guaranteed by the manufacturer for satisfactory service for a
minimum period of 18 months from the date of receipt or one year after
commissioning, whichever is earlier. The manufacturer shall replace the unit /
components free of charge to the satisfaction of purchaser in case of failure due to
material flow, poor workmanship or design defect during the guarantee period.
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13.2 However different plants/ Units might have different norms for guarantee/ Warrantee
clause. Keeping in view of this practice, each plant unit mention the Guarantee/
Warrantee clause as per their own standard Practice Norms.

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13.3
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TABLE-2A
INPUT KW RATING OF CLASS - 2 DUTY DOUBLE STAGE HORIZONTAL GEAR BOX
(Clause 3.1)

TYPE INPUT NOMINAL RATIO

RPM 8 12 16 20 24 31.5 40 48
600 5.64 4.26 3.56 2.88 2.53 1.84 1.38 1.15
DHR 250 750 6.21 4.60 4.03 3.56 3.10 2.18 1.72 1.50
1000 6.78 5.52 4.60 4.02 3.56 2.64 2.42 1.84
600 15.30 11.16 9.32 6.90 6.21 4.72 3.34 2.76
DHR 350 750 17.48 13.11 11.16 8.16 7.48 5.75 4.14 3.45
1000 21.39 16.10 13.92 10.58 9.54 7.48 5.52 4.60
600 19.09 14.26 11.96 10.70 9.32 6.32 5.75 4.48
DHR 400 750 21.04 15.64 13.22 11.96 10.46 7.59 6.56 5.18
1000 22.66 18.63 15.41 13.46 12.19 9.08 8.05 5.75
600 43.70 23.35 28.18 22.77 20.24 14.84 11.16 9.32
DHR 500 750 48.88 36.80 31.05 27.60 24.15 17.36 13.80 11.62
1000 52.90 43.12 35.65 31.62 28.18 20.82 18.06 14.60
600 86.25 65.55 54.62 48.30 41.98 29.32 25.88 20.58
DHR 650 750 95.45 71.30 60.95 54.62 47.15 33.35 29.90 23.58
1000 103.50 83.95 69.00 64.40 55.20 40.82 36.22 28.75
600 105.65 115.00 96.60 78.20 70.15 50.60 38.52 32.20
DHR 750 750 167.90 126.50 106.95 95.45 83.95 59.80 47.15 39.68
1000 149.50 121.90 108.10 97.75 72.45 62.10 50.60
600 241.50 172.50 143.75 108.10 94.30 72.45 52.90 44.28
DHR 850 750 264.50 200.10 173.65 131.10 116.15 88.55 65.55 54.62
1000 235.75 193.20 162.15 148.35 115.00 86.25 72.45
600 356.50 270.25 227.70 185.15 165.60 121.90 90.85 74.75
DHR 1000 750 299.00 253.00 225.40 196.65 142.60 112.70 94.30
1000 287.50 253.00 235.75 170.20 146.05 119.60

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TABLE-2B
INPUT KW RATING OF CLASS - 3 DUTY DOUBLE STAGE HORIZONTAL GEAR BOX
(Clause 3.1)

TYPE INPUT NOMINAL RATIO

RPM 8 12 16 20 24 31.5 40 48
600 4.83 3.56 2.99 2.42 2.18 1.61 1.15 0.98
DHR 250 750 5.29 3.91 3.45 2.99 2.64 1.84 1.50 1.26
1000 5.75 4.72 3.91 3.45 2.99 2.30 2.07 1.61
600 13.00 9.54 7.94 5.86 5.29 3.91 2.88 2.42
DHR 350 750 14.84 11.16 9.54 7.02 6.32 4.94 3.56 2.99
1000 18.17 13.68 11.84 8.97 8.16 6.32 4.60 4.02
600 16.22 12.08 10.12 9.08 7.94 5.40 4.94 3.80
DHR 400 750 17.82 13.34 11.27 10.24 8.86 6.44 5.64 4.37
1000 18.74 15.87 13.11 10.92 10.35 7.70 6.78 4.94
600 37.38 28.18 23.58 19.32 17.25 12.54 9.43 7.94
DHR 500 750 41.40 31.05 26.45 23.46 20.82 14.72 11.73 9.89
1000 54.85 36.80 29.90 26.45 23.58 17.71 15.41 12.42
600 73.02 55.20 46.00 40.82 35.65 24.72 22.08 17.48
DHR 650 750 80.50 60.38 51.18 46.58 40.25 28.18 25.30 20.01
1000 87.40 71.88 58.65 54.05 46.58 34.50 30.48 24.15
600 127.65 97.75 81.65 66.70 59.80 43.12 32.78 27.02
DHR 750 750 142.60 108.10 90.85 80.50 71.30 51.18 40.25 33.92
1000 126.50 103.50 92.00 82.80 60.96 52.90 42.55
600 204.70 146.05 121.90 92.00 79.35 62.10 44.85 37.38
DHR 850 750 224.25 170.20 147.20 111.55 98.90 74.75 55.78 46.58
1000 200.10 164.45 138.00 126.50 97.75 73.60 62.10
600 299.00 230.00 193.20 157.55 140.30 102.35 77.05 64.40
DHR 1000 750 235.00 216.20 190.90 165.75 120.75 95.45 79.35
1000 247.25 216.20 198.95 144.90 124.20 101.20

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TABLE-2C
INPUT KW RATING OF CLASS - 4 DUTY DOUBLE STAGE HORIZONTAL GEAR BOX
(Clause 3.1)

TYPE INPUT NOMINAL RATIO

RPM 8 12 16 20 24 31.5 40 48
600 2.53 1.72 1.38 0.98 0.86 0.63 0.46 0.40
750 3.22 2.07 1.61 1.15 1.04 0.80 0.58 0.46
1000 4.31 2.76 2.30 1.61 1.38 1.04 0.75 0.63
600 6.10 3.91 3.10 2.07 1.84 1.38 1.09 0.98
DHR 350 750 7.48 4.94 3.91 2.64 2.30 1.72 1.26 1.09
1000 10.00 6.56 5.29 3.56 3.10 2.30 1.72 1.44
600 11.73 7.70 6.10 4.48 3.91 2.88 2.18 1.84
DHR 400 750 14.72 9.66 7.70 5.25 4.83 3.56 2.53 2.18
1000 19.55 12.76 9.78 7.36 6.44 4.72 3.45 2.88
600 20.36 13.22 10.70 7.59 6.67 4.94 3.68 3.22
DHR 500 750 25.42 16.56 13.22 9.54 8.40 6.21 4.37 3.80
1000 30.82 22.08 17.71 12.65 11.16 8.28 5.98 4.94
600 48.30 31.62 25.30 18.17 15.87 11.84 8.86 7.70
DHR 650 750 55.20 40.25 31.62 22.42 20.01 14.72 10.58 8.86
1000 73.60 52.90 42.55 30.48 26.45 19.55 14.14 11.62
600 69.00 44.85 36.22 25.88 22.42 16.68 12.65 10.92
DHR 750 750 78.20 55.78 44.85 32.20 28.18 20.93 15.06 12.65
1000 67.85 59.80 43.12 40.25 27.37 20.12 16.68
600 95.45 61.52 49.45 35.65 31.62 23.00 16.90 15.06
DHR 850 750 108.10 77.05 62.10 44.28 38.52 23.75 20.58 17.48
1000 94.30 82.80 58.65 51.75 37.95 27.60 24.50
600 148.35 105.80 85.10 60.95 54.05 40.25 29.90 25.88
DHR 1000 750 120.75 105.80 75.90 67.28 50.02 36.22 30.02
1000 129.95 102.35 89.70 66.70 47.72 39.68

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