Project Snapshot | Crane Manufacturer

Client: Crane Manufacturer – Major OEM
Industry: Nuclear waste handling and decommissioning
Application: Power and control system design for nuclear waste handling crane
Location: UK
Services provided: Power and control system design, panel schematics and layouts, I/O definition, safety and redundancy integration for a nuclear waste handling crane
Design tool: AutoCAD Electrical 2024, MS Office
Drives & PLCs: Schneider Electric hoisting solution - Altivar Machine drives with Modicon M580-class safety PLC and associated I/O, tailored for crane/hoisting applications
Key result: Robust, safety-focused crane power and control system meeting nuclear waste handling requirements and supporting remote and local operation
Duration: 7 months from concept to issued-for-construction drawings

Client & Project Background

The client was implementing a nuclear waste handling system where an overhead crane is used to move high-integrity containers and equipment within controlled areas. Cranes in nuclear plants must meet stringent safety, redundancy, and reliability requirements that go beyond typical industrial cranes. APC Engineering Services was engaged to design the power and control panels, I/O structure, and safety functions for the crane using AutoCAD Electrical 2024 and Schneider Electric drives and PLCs suitable for hoisting applications.

Challenge / Requirements

The crane had to handle critical nuclear waste loads with high reliability, including precise hoisting, trolley, and bridge movement, and controlled positioning under both normal and remote operation modes.
Safety and regulatory expectations demanded redundant protections, overload prevention, travel limits, and interlocks, as well as clear separation between safety circuits and standard control circuits.
Control panels, field devices, and cabling needed to be engineered for harsh, high-radiation or restricted-access environments, supporting remote diagnostics and minimal maintenance interventions.
The solution had to integrate Schneider Electric hoisting drives and PLCs in a way that supports safe motion control, fault monitoring, and interface with higher-level plant systems.

Solution (APC approach)

1. Power and Control Design

Used AutoCAD Electrical 2024 to develop detailed power and control schematics for crane hoist, trolley, and bridge motions, as well as auxiliary systems (brakes, lighting, cameras, limit switches).
Selected Schneider Electric drives (Altivar-series for hoisting) and a Schneider PLC platform suitable for crane and hoisting control (e.g., Modicon M580-based architecture with appropriate I/O and safety modules), applying manufacturer guidelines for hoisting applications.
Designed panel layouts with clear segregation of power, control, and safety circuits, using AutoCAD Electrical panel layout tools and manufacturer catalog data for Schneider components.

2. Safety, Redundancy, and Limits

Engineered redundant limit devices for hoist and travel motions (upper/lower hoist limits, end-of-travel for trolley and bridge), integrated into both the standard PLC logic and independent safety circuits.
Implemented emergency stop chains, overload protections, and fault-handling logic so that critical failures lead to safe state transitions while maintaining controlled stopping where possible.
Structured I/O and wiring so safety-related signals are clearly identified and traceable for inspection and testing.

3. Remote and Local Control Integration

Defined I/O allocation and control philosophy to support both local pendant/desk operation and remote operation from a control room, including camera and status feedback integrations.
Provided clear interface points for higher-level plant systems to monitor crane status, alarms, and interlocks.
Generated comprehensive device lists, terminal diagrams, cable schedules, and reports from AutoCAD Electrical to support installation, FAT, and SAT.

Results & Benefits

Delivered a complete power and control design package for the nuclear waste handling crane, combining AutoCAD Electrical 2024 schematics and panel layouts with Schneider Electric hoisting drives and PLCs selected for crane applications.
Enhanced safety and compliance by incorporating redundant limits, safety circuits, overload protection, and clear separation of safety-related functions, aligned with nuclear crane best practices.
Improved maintainability and commissioning through structured I/O allocation, standardized device naming, and detailed documentation generated from AutoCAD Electrical’s reporting features.
Enabled flexible operation and monitoring of the crane in a nuclear waste handling environment, supporting both local and remote control with strong diagnostics and fault visibility.

Tools & Technologies Used

Design: AutoCAD Electrical 2024 for intelligent schematics, panel layouts, automatic wire numbering, component tagging, and report generation, leveraging manufacturer catalog data for Schneider components.
Drives & PLCs: Schneider Electric hoisting control solution using appropriate Altivar drives and Modicon PLC platform for crane motion control, safety I/O integration, and diagnostics.
Application domain: Nuclear waste handling crane control, emphasizing redundancy, safety, remote operation, and compliance with nuclear and crane-related guidelines.

“APC Engineering Services provided a comprehensive power and control system design for our nuclear waste handling crane. Their use of AutoCAD Electrical 2024, combined with Schneider Electric drives and PLCs tailored for hoisting, gave us a robust and safety-focused solution. The quality of documentation and attention to redundancy and remote operation requirements have greatly supported our compliance, commissioning, and long-term maintenance needs.”

Case Study