FOR A TOUGH JOBTOUGH CRANES - · PDF filesations, repairs and spare part services. KCI...

KCI KONECRANES GROUP

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Headquartered in Finland, KCIKonecranes is a world leadingEngineering Group specialising in

advanced overhead lifting solutionsand maintenance services. KCIKonecranes competes in all parts ofthe industrial and harbour cranemarket.

KCI Konecranes’ activity is organisedalong three Business Areas: SpecialCranes, Standard Lifting Equipmentand Maintenance Services.

KCI Konecranes is the global leader incustom-engineered heavy-duty cranesfor process industries. KCI Konecranesperforms strongly in winning orders fornew cranes based on its high perfor-mance technology. KCI Konecranes’Special Cranes are highly sophisticat-ed cranes for a wide variety of processindustries and harbours and shipyards.KCI Konecranes is a global supplier ofspecial harbour cranes for bulk materi-als and containers and a leadingprovider of shipyard cranes.

Konecranes’ Standard Lifting Equip-ment Business Area provides the mostmodern product range for liftingcapacities of less than 50 tons. Thisproduct range includes industrial andexplosion proof cranes, chain and wirerope hoists, workstation cranes and avariety of crane components.

The importance to industry of propermaintenance of machinery and min-imisation of downtime has seen Main-tenance Services to become the sin-gle biggest Business Area of the KCIKonecranes Group, accounting for44% of sales. Maintenance Servicescover all activities necessary for trou-ble-free crane operation, from initialcommissioning to the end of thecrane’s economical life. These activi-ties include inspections, preventivemaintenance programmes, moderni-sations, repairs and spare part services.KCI Konecranes provides maintenanceservices for all crane makes regardlessof their original manufacturer.

In 2000, Group sales totalled EUR 703million (USD 649 million), of which 92 %was derived from outside Finland. KCIKonecranes has over 4400 employeesin 34 countries throughout the world.

WWW.KONECRANES.COM WWW.KONECRANES.COM

Petroleum Coke Handling

TOUGH CRANES FOR A TOUGH JOB page 3

34 Steel Mill Cranes toAvestaPolarit page 6

Intelligent Biofuel Cranes page15

TOUGH CRANES FOR A TOUGH JOB34 Steel Mill Cranes toAvestaPolarit page 6

Intelligent Biofuel Cranes page15

Petroleum Coke Handling

page 3

The seven process crane companies operating within theKCI Konecranes Group form the Global Crane Company(GCC). These companies are located in Finland, the UK,

Germany, France, the US, Singapore and China. The GlobalCrane Company designs and manufactures process cranesand offers modernisation services for existing cranes.

Process cranes refer to overhead travelling cranes includ-ing gantry cranes that form an essential link in our customers’production processes; any malfunction in these cranes wouldrapidly disable the customer’s entire production line. Typicalcustomers include the paper industry, steel mills and steel pro-cessing where every ton of paper or steel whose production isinterrupted equates to losses for the manufacturer, losses thatcan easily add up to hundreds of thousands of euros within afew hours of production being halted.

Our SM- winch range illustrates the success of our innova-tive R&D; the range consists of six basic frame sizes handlingloads of up to 400 tons. These are constructed from preciselymachined parts that ensure reliability under heavy use. Weproduce in-house all the motor drives and computer automa-tion for the cranes. We do not use components from differentmanufacturers; instead, we design and manufacture inte-grated solutions. Similarly, we do not rely on traditional solu-tions but, instead, strive to produce cranes in which perfor-mance and reliability are optimally combined at competitiveprices.

Our process crane customers are continuously striving toincrease their production capacity by removing any per-ceived bottlenecks. As a result they will also demandincreased performance from their cranes. The modernisationservices that our companies offer can significantly increasethe reliability and performance of a crane by combiningtechnology know-how with modern crane components. Dueto the heavy-duty nature of process cranes, most units willundergo modernisation many times during their life span. Ourmodernisation service companies modernise all cranesregardless of original manufacturer.

We pride ourselves on being close to our customers. Thecompanies that form the Global Crane Company are locat-ed in our main markets. With the combined productioncapacities of the different companies we can also handleparticularly large projects efficiently guaranteeing short deliv-ery times to our customers.

The Global Crane Company is agrowing, innovative, reliable andsuccessful provider of cranes andrelated services. All cranes work onpaper, but our cranes also work asan integrated part of our customers’production processes.

Antti Vanhatalo, President, Process Cranes Business LineKCI Konecranes International Plc

PETROLEUM COKE HANDLING

Many oil refineries utilize aprocess called “DelayedCoking” to convert petroleumresiduum into marketableliquid and gas products. Theprocess allows the use oflower grades of crude oil withhigher sulfur content. Therefineries can extract highervalue products whileconverting wastes into coke,which has economic benefitssuch as fuel for power plants.The term “delayed” is used todefine where the cokingoperation takes place in therefinery process. It is sonamed because the coking offeed material is delayed untilit arrives at the coking drumsthat are downstream of theheater.

TOUGH CRANES FOR A TOUGH JOB

3N o 6 K O N E C R A N E S ’ W O R L D2 K O N E C R A N E S ’ W O R L D N o 6

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PETROLEUM COKE HANDLING

PUBLISHER KCI KONECRANES INTERNATIONAL PLCP.O.Box 661FIN-05801 Hyvinkää, FinlandTel. +358 (0)20 427 11Fax +358 (0)20 427 2099

EDITOR IN CHIEF Franciska Janzon, Manager, Group CommunicationsKCI Konecranes International PlcTel. +358 (0)20 427 2043Fax +358 (0)20 427 [email protected]

PRODUCTION OnePartner Oy and KCI Konecranes International Plc

COPYRIGHTS KCI Konecranes International Plc

PETROLEUM COKE HANDLING– TOUGH CRANES FOR A TOUGH JOB ............................ 3

34 STEEL MILL CRANES TO AVESTAPOLARIT .................... 6

HEAVY CAPACITY CRANES FOR SOUTH AMERICAN HYDRO POWER STATIONS ............................ 8

THE SM-WINCH RANGE INCREASES CAPACITY .............10

POWER PLANT CRANES TO SIEMENS IN PHILIPPINES ..... 11

THE FUTURE OF PAPER MILL CRANES: CONSUMPTION MEETS AUTOMATION .......................... 12

INTELLIGENT BIOFUEL CRANES HANDLINGDRY STRAW IN SPAIN ................................................... 15

CRANES FOR THE WORLD'S LARGEST PAPERBOARD MACHINE AT PAPIERFABRIK PALM, GERMANY............. 16

KONECRANES (UK) AND THE STORY BEHIND JAGUAR’S LATEST MODEL ........................................... 18

MAINTENANCE PROGRAM AIMED AT KEEPING CRANES ON MOVE...................................................... 20

KONECRANES MODERNIZES GANTRY CRANEFOR DYCORE OF THE NETHERLANDS............................ 21

UPM-KYMMENE: MODERNISATION OF PAPER MIIL CRANES ENSURES UNITERRUPTED PRODUCTION ... 23

DYNA2002 – SUPERIOR CRANE DRIVE TECHNOLOGY .. 24

KONECRANES’ NEW PREMIUM SYSTEM FOR HIGHERCRANE SAFETY AND PERFORMANCE CONTROL .......... 25

NEW CUSTOMER SATISFACTION SURVEY AT KONECRANES COMPONENTS CORP............................ 26

GEAR FACTORY BEGINS PROFILE GRINDING OF GEAR WHEELS ........................................................ 27

KCI KONECRANES GROUP AT A GLANCE ............ 27–28

EDITORIAL

WWW.KONECRANES.COM

FOCUS:PROCESS CRANEPROJECTS WORLWIDE


Petroleum Coke is formed inlarge vertical coke drums thatare filled with hot oil, whichcondenses to a solid massduring the coking process. It isremoved from the drum by

drilling a pilot hole down through thecoke and then breaking it up with hori-zontal water jets. The coke breaks up intosmaller pieces and falls into the coke pitbelow the drums. It has the appearanceof porous coal and it can range in sizefrom gravel to boulders. The density of thecoke is roughly 40 to 65 lbs. per cubic ft.

Many refineries have recently upgrad-ed their processes to include the additionof a coking operation. It is a significantinvestment but the economics are justi-fied. With the new coking operationcomes the requirement to handle thecoke that is produced. This is where KCIKonecranes enters the picture.

Coker cranesAfter the coke is produced it is dis-

charged from the drums into a concretelined pit. Depending on the type of oper-ation, the coke is moved with a craneeither to a drying pad or directly to ahopper/crusher for transport from therefinery.

The coker cranes operate directlyover the coke pit in a very humid, causticenvironment. They can be either bridgeor semi-gantry type with spans betweenabout 90 ft. to 150 ft. Lift heights canrange from 80 to 95 ft. Speeds are as highas 275 FPM for the hoists and trolley andusually less for the bridge or gantry.

The capacity of the crane can rangefrom about 15 short tons with an 8 cubicyard bucket up to 45 tons with a 25 cubicyard bucket. The clamshell type bucketsare designed specifically for handling thehot, wet coke and have perforated shells.They operate with two holding and twoclosing lines. The trolley has separate

KONECRANES TECHNOLOGYADVANTAGE

Like many process cranes, thesuccess of a coker crane ismeasured by it’s reliability and lowmaintenance. KONECRANES hasbeen able to distinguish its craneswith many proven features such as:

■ Air-conditioned and pressurized con-trol houses that provide a clean envi-ronment for the controls insuringlonger life.

■ Robust design to CMAA class "F" crite-ria for long life and low maintenance.

■ All wheel drive trolleys for better high-speed travel in wet weather and driveredundancy.

■ State-of-the-art Dynahoist and Dynaccontrols with built-in maintenancediagnostics allowing faster and moreaccurate trouble shooting.

■ Dynagrab hoist synchronizer, whichgives the operator precise control ofbucket opening and closing and hascontributed to exceptionally longrope life.

■ Hoist motors have external blowers forsuperior cooling and they are also rat-ed for continuous operation

■ Special epoxy coatings on the cranestructure for durability in the harshenvironment over the coke pit.

■ All exposed electrical enclosures arestainless steel for corrosion resistance.

■ Heat-treated rope drums for extendedtime between drum replacements.

■ Konecranes exclusive “CAROL” systemfor extended maintenance diagnos-tics and record keeping.

KCI Konecranes has built a strong repu-tation for reliability in this very demand-ing category of applications. Accordingto one operator - compared to the oth-er cranes he has used, Konecranes'crane is "the Rolls Royce of the industry".

The operator of the lower, auxiliary cab located next to the hopper chutemanually drives the gantry to position the hopper, and controls operationof the hopper gates to discharge the coke into the rail cars. A hands-freevoice communication system between upper and lower cabs allowsoperators to coordinate their tasks. Computerized overload protectionhardware and software ensure safe operation of the crane by eitheroperator.

The upper cab is the primary control center of the crane, operating an 18 cubic-yardclamshell bucket, which loads the hopper. PLC automation streamlines this function with four

zone return panel buttons which enable the bucket to automatically return to a selected pitzone after the operator manually drops a load into the hopper. In the background, the second

crane is seen filling the hopper, which holds 27 cubic yards of coke.

hoist units, one to operate the holdingropes and the other for the closing ropes.

There are many years of coker craneexperience within the KCI Konecranesfamily. Landel and Kranco produced thefirst cranes more than 15 years ago. Draw-ing from this experience, KCI Konecranesproduced the first cranes with 100%Konecranes technology in 1996. Thesewere for the Lyondell Citgo refinery inHouston, TX.

Preferred contractor for a groundbreaking design

KCI Konecranes was selected by engi-neering consultant Foster Wheeler to

implement its design for an innovativenew coker crane. The twin 27-ton single-leg gantry cranes contracted for LyondellCitgo Refining’s Houston, TX coker opera-tion were the first to be designed with atraveling hopper integrated into thegantry. In addition to its usual role as adirectional funnel, the location and struc-ture of the hopper is designed to “holdand carry” a full load of coke to rail carspositioned past the pit, eliminating theneed for expensive, maintenance pronecar pullers.

The “hold and carry” feature, very dif-ferent from a traditional pass-through hop-per, was conceived by Lee Merville of Fos-

ter Wheeler to shorten cycle times. Itrequired a crane strong enough to carryeach load twice— first with a bucket toload the hopper, and then with the hop-per itself. Konecranes provided sophisti-cated systems for dual operator coordina-tion and overload control. The designmandated heavier than normal bridgestructure and larger drives, motors, brakesand running gear than those required bycranes servicing an unattached, pass-through funnel hopper. The CMAA class“F” cranes feature AC stepless controlsperforming at 275 fpm for the hoist, 200fpm for the trolley and 125 fpm for thegantry, and a hydraulic flow control sys-tem allows each crane to load 4 rail carsper hour. In addition, the cranes areexpected to perform reliably for 24-hourcontinuous duty in an outdoor, unprotect-ed location under severe atmosphericconditions. During initial performancetests, 27 rail cars were successfully loadedin one shift.

For Konecranes, this project provideda unique challenge to develop a crane

that would meet the specificationsdesigned by the engineering company,and perform additional tasks that no previ-ous coker crane had been asked to do.Although the design continued to evolveas customer throughput and processrequirements were finalized, KCIKonecranes worked closely with FosterWheeler to refine their specifications anddevelop a quality Konecranes solution.Since that time KCI Konecranes has sup-plied cranes for many other projectsincluding:■ Conoco Melaka Refinery, Malaysia.■ Pemex, Tampico, Mexico. ■ Marathon Oil, Garyville, Louisiana■ Hovensa Refinery, St. Croix,

Virgin Islands■ Sincor Refinery, Jose, Venezuela■ Petrozuata, Jose, Venezuela ■

Doug Maclan, Vice President, Marketing and sales

Konecranes America [email protected]

AvestaPolarit becomes the world’s largest stainless steel producer

KCI KONECRANES TO DELIVER

THIRTYFOUR

STEEL MILL CRANES TO TORNIO

reliable and work with precision. No addi-tional stoppages are permitted, becausethe material has to move continuouslythrough the process,” he stressed.

”We’ve had a long co-operation withKonecranes and have learned that wecan rely on quality deliveries from them.Over the years, we’ve forged a closeworking relationship, and Konecranes hastailored very practical crane solutions tomeet our often exceptional needs. Thiscertainly weighed heavily in our choice,”concluded Seppo Koivuniemi.

Reliable deliveries an important factor

Aside from quality issues, delivery relia-bility was also an important factor inchoosing a supplier. The customer needsto be certain that a supplier can keep tothe agreed schedule so that the projectprogresses according to plan.

”In industrial investments, cranes typi-cally play a crucial role in the entire invest-ment. They are often first used during theconstruction phase, when they must beworking in accordance with the agreed

schedule. Otherwise the entire projectcould be delayed,” notes Seppo Koivu-niemi.

He said that for this project as in previ-ous ones, everything has gone as planned.There have been no ploblems andAvestaPolarit is pleased with Konecranes’ability to meets its delivery commitments.

”We have had a longer partnershipwith Konecranes’ than with other equip-ment suppliers and the company has adeep insight into our processes and relat-ed special requirements. As customers, wehave also long been involved in specifyingcranes to suit our own needs. Konecraneshas greatly improved its ability to take spe-cial customer needs into account. Thishad a decisive impact on our choice ofcrane supplier,” Koivuniemi points out.

Major Crane OrderAvestaPolarit made the investment

decision to go ahead with the Tupla pro-ject in December 1999. Work first startedon building the melting plant and hotrolling mill. This was followed by the coldrolling mill, which is still under construction.

Work on installing the equipment is alreadyunderway in the melting plant and hotrolling mill and these are scheduled tocome on stream as planned in July 2002.Work on installing equipment in the coldrolling mill will commence early next yearand the mill is scheduled to start up inautumn 2002.

The size of AvestaPolarit’s investmentalso means that by international stan-dards, the delivery is a major one in theindustrial crane business. Konecranes is todeliver a total of 34 cranes to Tornio: 11process cranes and 23 erection and ser-vice cranes. Depending on the finalscope, the entire order is worth €18 –20 mil-lion,” says Kari Mustakallio, sales managerat KCI Special Cranes. ■

Kari Anttila, General Marketing ManagerKCI Special Cranes Corp.

[email protected]

The AvestaPolarit steel plant in

Tornio, Finland has launched a

massive investment project named

Tupla (Double). The total project is

valued at over € 670 million and is

the largest industrial investment in

Finland since the last nuclear power

plant. KCI Konecranes is playing an

important part in the investment

project, with the delivery of a total

of 34 EOT (electric overhead

travelling) cranes.

6 K O N E C R A N E S ’ W O R L D N o 6 7N o 6 K O N E C R A N E S ’ W O R L D

volume and at peak their construction willprovide jobs for 800. This means 600 man-years of work. The investment will bring 150permanent new jobs to Tornio.

Cranes are at the heart of the production process

AvestaPolarit was extremely carefulabout choosing the many equipment sup-pliers involved in the project.

”We operate in a fully global market.

We can’t choose a company justbecause it’s Finnish, there has to be a cer-tain added value. That’s why we alwayslook at operating criteria when buyingequipment. Naturally price is also impor-tant, but our choice can’t be based onprice alone.”

Process cranes play a vital role in ouroperation. These heavy-duty cranes areused to move laddles, slabs and coils. Theautomatic cranes have to be extremely

After the investments at the Tornio plantAvestaPolarit Stainless will become the world'sleading manufacturer of refined steel, with amelting capacity of 2.5 tons. Konecranes is asignificant partner in the investment project, asit will supply a total of 34 cranes to the newplant", says Seppo Koivuniemi, Vice President,Projects at AvestaPolarit.

After the new facitity is completeAvestaPolarit Stainless will have a2.5 million-tonne smelting capaci-

ty, thus making it the world's largest pro-ducer of Stainless Steel, says Seppo Koivu-niemi, Vice President, Projects at Avesta-Polarit. The increase in capacity was pri-marily driven by rising sales of stainlesssteel and promising future prospects.

“The Tornio plant had alreadyexpanded production capacity manytimes in the past. Further improvements tothe old facility were not feasible, so Aves-ta’s best option to take advantage offavorable market conditions for stainlesssteel was to invest in a completely newinfrastructure.

Excellent growth forecasts confirmedour motivation to go ahead with the pro-ject. Since then, demand has risen byover 5 per cent a year,” says Koivuniemi.

A total of more than 10 hectares ofcovered factory surface area are to bebuilt at the already extensive Tornio plant.The largest industrial halls are 600 and 700metres long and 30 metres high. The newbuildings will be 2.7 million cubic metres in The delivery includes this charging crane with alifting capacity of 350 tons and a span of 28 m.

Case: Caruachi of Venezuela

In the tendering stage of a project, theConsulting Engineer should know theavailable technical solutions, crane con-

figuration and benefits. For the crane mak-

er, influencing the consultants’ specifica-tions for the project is often difficult. How-ever, when the crane maker understandsboth the consultants’ thinking and newpossibilities offered by developing technol-ogy he can offer solutions, that shows hisown experience and substantially benefitthe end customer. The consultant in thiscase was the Venezuelan subsidiary of theglobally acting American company HarzaEngineering.

In the offer process, the crane maker

will be evaluated favourably if he has suc-cessfully performed projects for the cus-tomer in the past or can list similar or largerprojects as references. This is why excel-lent customer service is always a top priori-ty. The end customer was C.V.G Electrifi-cación del Caroní (EDELCA), Venezuela.EDELCA is a government utility, which pro-duces approx. 75 % of the country’s elec-tricity.

The contractor who sells the project tothe end customer must be well served on

previous projects, both technically andcommercially. The customer remembersgood service and well executed warrantyissues for a long time. The plant machinecontractor was Kvaerner Energy A.S.,today GE Hydro.

The letters C.C.C. (Consultant – Cus-tomer – Contractor) formed an importanttriangle, the crane maker needs to be inthe center. When the crane maker hasunderstood the inquiry specifications forthe project, he has the opportunity tooffer solutions on how to improve thespecifications for better crane perfor-mance. Most clarifications such as, discbrakes, modern controls, properly calcu-lated motors turn into positive argumentsand benefits for the customer.

In long term projects, such as Caru-achi, one of the larger Hydro Power Sta-tions in Americas, the terms of contractare very important, mutually for the pur-chaser and the seller. Bonding for the pro-ject must provide sufficient guaranteethat the financing and warranty periodsare covered to the customers’ satisfac-tion.

Project management experiencemust be adequate to the needs of C.C.C.


NEW APPLICATIONS OF LARGE CAPACITY CRANES

Heavy capacity cranes for South American hydro power stations

The 790 t x 26.55 m EOT crane for Caruachi during construction in Hanko Works. Each trolley weighs46 t and has a lifting capacity of 395/50 t.

The erection of the 790 t crane wasexecuted in four main steps: the 1stmaingirder, the 2nd maingirder and thetwo winches each with a 395 t liftingcapacity and a lifting height of 45 m.

Reliable works turns to new project

The Caruachi project also includes thedelivery of slide gate gantry crane.Konecranes is to design the slide gategantry crane with a capacity of 3 x 140 tand a lifting height of 59 m for the Caru-achi Dam on the Caroní River inVenezuela. Konecranes is also responsiblefor the supply of the mechanical andelectrical components, which will bedelivered to Alstom Power Ltd Taubate,Brazil. Alstom is the main contractor forCaruachi Dam’s slide gate project.

The whole project with 12 x 180 MWturbines and generators will be equippedwith Konecranes crane technology. Thedifferent units at the Caruachi Plant arescheduled to start energy productionbetween the years 2003 – 2006, for thesteel mills and aluminium industry at Puer-to Ordas and for export to Brazil.

Konecranes’ Taisto Järvinen has kepttabs on EDELCA’s Power Plants on theCaroní River for over 20 years. EDELCAbuilt the first power plant on the CaroníRiver 25 years ago. The Guri plant hadtwenty turbines and units and the facilitywas equipped with Japanese cranes. Itwas at the same time that Konecranesdelivered its first 280 t capacity crane toCadafe, a government owned thermalpower station company located inMoron, Venezuela. EDELCA then contin-ued with another large power plant pro-ject named Macagua. For this projectKonecranes was contracted to supplylight lifting devices to the plants. Onlyafter 15 years of very intensive salesactions, Konecranes was awarded its firstlarge crane project to EDELCA andreceived the order for the large cranes tothe Caruachi power plant. A point ofinterest: The Caroní river begins at SaltoAngel – Angel Falls, at 979 m the world’shighest free water fall. ■

Taisto Järvinen, Sales Director, KonecranesComponents Corp., is familiar with the Caroníriver from Angel Falls down to the Orinago riverand its power plants that have a joint installedcapacity of 13000 MW. When completeCaruachi, Guri, Macagua and the futureTocama plant will together represent a totalinstalled capacity of 17 000 MW.

–partners and to insure that the perfor-mance data, agreed project scheduleand the estimated cost can be kept.

Well co-ordinated site activities andgood execution of site services, provesthe crane makers' competence andensures that the customer remains agood reference for the next project.

It is important that the customer andcrane maker finalise the load testing andcommissioning on schedule without along punchlist.

Large projects include several steps insales and project management, eachof which has a role to play.

The Santa Rita Power Plant is locatedat a 3 hours drive South of Manila. It isone of the privatised power plants

built by First Gas Power Corp, a JV compa-ny between the large local conglomerateFirst Philippines Holdings Corp and BritishGas. The plant is being built in 4 blocks,each generating 250MW of electricity. Allthe 4 units of the 300T EOT cranes suppliedby Konecranes are equipped with state-of-the-art inverters, stepless speed controlsystem and Spacemaker SM11 trolleys.

Even before the completion of theplant, Siemens clinched a second orderfrom First Gas at a site next to Santa Ritafor a 500MW plant at a cost of US$250m inMarch 1999. Amidst fierce competitionfrom European and Korean makers,Konecranes emerged as the winner of 2

similar 300T cranes for this new projectcalled San Lorenzo Power Plant. Kone-cranes completed this turnkey delivery inApril 2001, less than 10 months from theorder date.

Konecranes’ success stems from theability to understand customer require-ments and to meet their stringentdemands on physical dimensions.

Time over time, the superior quality ofKonecranes products, high reliability, mod-ern technology and experienced projectmanagement teams compose Kone-cranes’ formula for success. In addition,Konecranes’ unrivalled extensive world-wide service network is often the primeconsideration for customers’choice ofvendor.

Konecranes Pte Ltd is a member of

Konecranes’ Global Crane Company(GCC) which consists of Process Cranecentres in USA, France, Finland, Scotland,Germany and Singapore. ■

Mak Tek KongRegional Manager, Engineered Cranes, Asia Pacific

Konecranes Private Limited, [email protected]

The New SM 12 model will be theheaviest standard winch on themarket.Basic features:

■ max. capacity 500 t Fem M3■ drum diameter 1600 mm■ rope diameter 36 mm■ lifting height with 16 ropes 45 m■ planetary gear replaces the usually

used open reduction on the drum


In February 1999, Konecranes Pte Ltd, KCI Konecranes’ subsidiary inSingapore successfully handed over the 4th EOT Crane with three hooks withlifting capacities of 300 t, 16 t and 2 t to Siemens for their 1000MW CombinedCycle Power Plant project in Santa Rita, Philippines.

POWER PLANT CRANES TOSIEMENS IN PHILIPPINES

Konecranes technology and components in a1000 t tandem lift at Machadino Hydro Plant,Brazil.

Konecranes Pte Ltd has contracted2 units of 370T Cranes for SerayaPower Plant in Singapore. The firstunit was handed over to Siemens-Samsung consortium in August2001. The entire project will becomplete in December 2001. These2 cranes are believed to be thelargest Power Plant Cranes in EastAsia Region.

L A T E S T

N E W S

provide 400 t capacity and 34.9 m liftingheight.

The new SM 12 meets all Europeanstandards as well as CMAA (CraneManufacturing Associations of America)requirements. ■

Taisto Järvinen, Sales DirectorKonecranes Components Corp.

[email protected]

Konecranes Components Corp. hascalculations and plans ready for theproduction of the new SM 12 -winch,

which constitutes the heaviest standardwinch available on the market.

KCI Konecranes designed the new SM12-winch for projects needing more liftingcapacity (up to 500 t) or lifting height (upto 45 m). The existing SM 1116 -winch can

Case: Machadino of Brazil

Konecranes Components Corporationalso was contracted for a project inBrazil. The order included the basic

engineering and mechanical componentsfor the Machadino Hydro Plant in Brazil.

Alstom Power in Taubate, Brazil was themain contractor for the plant’s turbinesand cranes.

The technology was specified for twoEOT cranes of 500 tons of lifting capacityand a lifting height of 21 m used in tan-dem. The cranes were completed this

year and the first rotors for the generatorare erected using a 1000 t tandem lift. ■

The SM-Winch range increasescapacity from 400 t to 500 t

Heavy capacity cranes for South American hydro power stations POWER PLANT CRANES TOSIEMENS IN PHILIPPINES POWER PLANT CRANES TOSIEMENS IN PHILIPPINES POWER PLANT CRANES TOSIEMENS IN PHILIPPINES POWER PLANT CRANES TOSIEMENS IN PHILIPPINES

L A T E S T

N E W S

In the past, automatic storagecranes were “tailor-made” byKCI Konecranes to fit each cus-

tomer’s needs. Features and sen-sor solutions were designed case-by-case. The experience andengineering know-how gainedthrough these projects ledKonecranes Components Corp. todevelop a new PD (Process Duty)Winch for automated applica-tions. Each of these applicationsuses some kind of gripping equip-ment, grapple, spreader or vacu-um lifter to pick up and transportthe load. Key elements of thisnew space-saving PD Winchinclude a loading device powersupply cable wound on the ropedrum directly, with slip rings at theidle end of the drum. The samechannel transfers the limit switchinformation. This design saves space andreduces the number of wearing compo-nents. The PD Winch is ideal for all loadingdevice applications, like waste-to-energygrab use, coil storage, or practically anyapplication within applicable load rangeusing a loading device, which is electrical-ly powered.

For the paper industry, the long historyof Konecranes’ Autostore automatedpaper reel storage vacuum lifter (VLU)continues with the latest version, whichincorporates the benefits of the new PDWinch. The Autostore vacuum lifter opti-mizes warehouse space by stacking rollsvertically several rolls high. Paper mills saveon floor space, equipment, labor and rolldamage costs because forklifts are notneeded with the Autostore system, whichstores, tracks and retrieves each roll indi-vidually using sophisticated automationsoftware. In the newest version of Auto-store, safety features for power cut-offs

and all function controls have beenupdated with the latest components andinverter technology. This new lifter is lighter,smaller and more energy efficient, requir-ing less hoisting capacity to operate, whiledelivering even smoother automation andstill better reliability. The space-savingdesign means that often the customercan save the price of the crane simply bylowering the building’s overall dimensionby one to two meters compared with theearlier designs.

Konecranes’ customers who use Auto-store systems estimate that their invest-ment in automation pays for itself in twoyears or less. In addition to the cost bene-fits already mentioned, Autostore savesmoney by eliminating lost rolls that mustbe remade, by improving timely deliveryof reels out of storage to the sheeters, andby facilitating just-in-time delivery to cus-tomers.

CONSUMPTION MEETS AUTOMATION

As you read this, hundreds of modernpaper machines are at work all overthe world, and every ton of paperthey produce is handled by KCIKonecranes’ Spacemaker Cranes.These cranes do more than simplyhandle paper – as each new facility isbuilt they are used to erect the papermachines themselves, and then tomaintain them on a monthly basis.


THE FUTURE OF PAPER MILL CRANES:

For centuries, paper has been theprime medium through which wecommunicate. But in today’s era of

electronic technology, it is valid to won-der if we’ve reached the apex of growthin the paper industry.

E-mail, umts, Ubicomp, E-Business, 3G,

New Winch, New Vacuum lifter

the Far East in the form of new paper mills.In North America and Europe, much ofthe growth will be achieved throughmodernisation and consolidation in theindustry. We expect that new papermachine start-ups over the next 10 yearswill average two per month worldwide.Statistics published by paper machinemanufacturers indicate that the trend toincrease machine widths is slowing down,but running speeds are increasing. It nowappears that producing paper at aspeed of two kilometers per minute permachine is no longer a dream but a reali-ty, achieved through precision machineconstruction, lighter structures, vibrationanalysis and other improvements through-out the papermaking process.

As paper machines become moreprecise, handling of paper machine partsduring construction and maintenancerequires more precision as well. As for thepaper itself, today’s ceramic roll coatingsdo not forgive handling mistakes. KCIKonecranes’ Spacemaker Cranes includethe broad range of capacity, handlingspeeds, and positioning accuracy need-ed to service the paper machines of thefuture as well as the machines operatingand being modernised today.

Automation of the papermakingprocess and material handling in a mod-ern paper mill now corresponds to 5% ofthe total investment. Integrated convert-ing, coating and sheeting sections aremost effectively served by a fully auto-mated intermediate roll storage system.

In AS/RS (Automatic Storage/RetrievalSystems,) KCI Konecranes has built a solidreputation in the paper industry world-wide. Konecranes is a paper industry spe-cialist, and is the only supplier to engineerand manufacture all of the components,electrics, automation and storage admin-istration software needed under onebrand with ISO 9001 quality assurance.Customers in the paper industry andcountless other process industries under-stand the value of making only onephone call to one single source for spareparts, maintenance service, troubleshoot-ing or warranty items. ■

WLAN, TCP/IP, and hundreds of otheracronyms and abbreviations are a jungleagainst which many of us want a firewall.Portable electronic mail communicators,electronic newspapers, electronic booksand other gadgets that transfer data fromone place to another have changed theway we live, and even more sophisticatedtools continue to flood the market. Butdespite this electronic explosion, paperconsumption per capita in some industri-alised countries has risen to over 300 kgper year.

So, why is paper still so important?Many old eastern cultures are only nowbeginning to change centuries old habitsof information transfer, and there mobilephone networks and high-speed data net-works are still in their infancy. In the elec-tronically sophisticated areas of the world,the newest digital cameras, games, soft-

ware and computers sold all require pack-aging. And, digital photo images are nowoutput at home— by cost effective print-ers on expensive photo quality paper!Despite predictions to the contrary, books,newspapers and magazines have yet tobe replaced by a solar powered screen towhich you download the morning newswhile preparing your coffee. For most ofus, the feel of high gloss coated paperunder our fingertips appeals to our per-ception of qualified content.

All of these factors explain why paperconsumption continues to grow. Thefastest growing areas are in the Far Eastand South America. If today’s consump-tion of some 350 million tons paper peryear continues to grow at the current rate,ten years from now the yearly consump-tion will be at 450 million tons.

Half of this growth will be realised in

Konecranes’ Autostore Vacuum lifter


Manual > Semi-automated > Fully automated operation

A mule can hardly be transformed intoa horse, even if it is trying hard and paint-ed black. Similarly, an automatic cranemust be designed from the beginning tobe an automatic crane. What makes thedifference is the position measuring equip-ment and the data input, working with

built-in safety systems. And the higher theautomation level, the stricter the safetyrequirements become. A system that canbe counted on to perform flawlesslyrequires the electrics and equipment forthe basic functions (manual) plus the x-ypositioning (semi-auto) equipment andfeatures, and finally, all the data inputs,safety systems, interlocking and computer

capability required for unmanned opera-tion (fully-automated). The enclosed blockdiagram aims to explain the alternatives tobe considered when defining the function-al specification. Only then can the cus-tomer realize all of the benefits of papercrane automation. ■

Hannu Piispanen, Sales Manager, Konecranes Components Corp.,

[email protected]

At Sangüesa Straw-fuelled PowerStation the three new automaticcranes not only unload the hay-

bales from the truck as ordered by theoperator, but they also control the qualityof the fuel received before accepting orrejecting it for transfer to storage. Thebale yoke, able to pick up 12 bales atone grip from the truck is equipped withmoisture measuring devices developedby Konecranes A/S. All wet bales arerejected and returned back onto thetruck. In addition, the moisture content ofall bales is measured and registeredbefore accepting them into storage.

The storage administration is fullyautomatic. For safety reasons the opera-tor commands the pick-up of the balesduring lorry unloading. After the “LorryUnloading Mode” is finished, the operatorcan activate the “Feeding Mode”. Fuelfeeding from the storage to the boilerconveyor is fully automatic.

Operator interfaceThe computer screen informs the

crane driver of:– Status of the crane (hoisting, moisture

measuring, weighing…)– Operator information (Bales too wet,

bales ordered in first priority to convey-ors etc…)

– Alarm information (overload, balesdropped, motor overheating…etc)

– Layout of the bales in the storage– Measuring results of the weighing and

the moisture measuring equipment

Semi Automatic Operation (Truck Unloading)

After the lorry has been positionedunder the crane in the unloading areathe operator lowers the bale yoke manu-ally on the bales. A video camera helpsthe crane driver to position the arms ofthe yoke. When the bales are lifted freefrom the lorry the crane driver activates abutton labelled “Start Semi automation.”

Intelligent biofuel craneshandling dry straw in Spain

The crane automatically performs the fol-lowing operations:– Bale yoke is lifted up to top position.– Moisture and weight are registered.– If moisture percentage is accepted the

crane moves towards the storage area.When the crane has passed the lorrylanes, an acoustic signal is given andautomation takes over command ofthe crane. The operator can nowrelease the controllers. The crane trans-fers the bales automatically to the posi-tion selected by the storage administra-tion system. If the boiler conveyorneeds the bales at the same time theload is re-prioritised and diverted to theconveyor.

Fully Automatic operationThe fully automatic mode is used

when the “Lorry Unloading Mode” hasbeen completed. The crane operatoractivates “Auto Mode” and the followingoperations are automatic:– The crane moves automatically to the

position in the storage area from wherethe next bales will be picked up.

– When the conveyor gives the signalthat more bales are needed, a pack-age of 12 bales is picked up from thestorage area and automatically trans-

KCI Konecranes Biofuel Crane handling strawbales at Sönderjyllands Höjspaendingsverk inDenmark.

Project data ■ Crane design by: Konecranes

Components Corp.■ Crane automation by: Konecranes A/S■ Crane machinery by: Konecranes

Components Corp■ Crane manufacturing by:

Konecranes A/S■ Main Contractor: FLS miljø as■ Customer: Energia Hidroelectrica

De Navarra (EHN), Spain.

Crane data:■ SWL (Safe Working Load) 10200 kg x

span 20,7 m (2 pcs) + 19,8 m (1 pc)■ The bale yoke has six arms for handling

12 bales at a time.■ Free width of yoke 2100-3100 mm

(hydraulic adjustable)■ The crane can operate in manual,

semi automatic or fully automaticmode.

In September 2000 Energia Hidroelectrica De Navarra (EHN), Spain, ordered three fully automatic cranes for its Straw-fuelled Power Station in Sangüesa. The cranes were delivered in June 2001 and will start operation in 2002.

ported to the conveyor.– After completing delivery the crane

returns automatically to the next stand-by position in storage waiting for thenext conveyor command. ■

Antti Rekola, Project Manager, Konecranes Components Corporation,

[email protected]

CRANE LAUGH

KONECRANES SUPPLIES CRANESFOR THE WORLD’S LARGESTPAPERBOARD MACHINE


In the early summer of 1998, there weretwo companies left competing for thePapierfabrik Palm project in Eltmann,

Germany, KCI Konecranes and KulickeKran- und Stahlbau.

KCI Konecranes won the contract for aturnkey delivery of eight bridge cranes--the smallest being a 5t crane with a 14mspan and the largest with 80t of liftingcapacity and a 23m span. The orderincluded delivery of all runways for Palm’snew paper mill, with deliveries starting in1999. The project was shared amongKonecranes companies: The wet end anddry end cranes including the cuttingmachine crane were built in France. Thecrane for machine roll storage was built inFinland and the standard cranes werebuilt in Austria. Project management wasshared between teams in Germany and in

Finland. Today the cranes have all beencommissioned and are in operation.Konecranes’ service organisation in Ger-many is currently preparing a capacityincrease on the dry end crane due toincreased tambour weights.

At the end of 2000, the same salesagent that forwarded the lead on the Elt-mann project contacted the manager inthat project, working now for Kulicke KraneGmbH in Berlin. (Kulicke Krane becamepart of KCI Konecranes early in 2000 and isnow known as Kulicke Konecranes GmbH.)The sales agent had a new lead on anupcoming project named “Rio Grande.”The name reminded us of the earlier casecalled Hong Kong Paper that turned outto be a project in Germany. We thereforeassumed that Rio Grande was also a codename.

Proven technologyAs we found out later, the inquiry

again came from Papierfabrik Palm — thistime for cranes to service the world’slargest cardboard machine and whatwould be the largest paper reel storageever built. We began technical discussionswith the customer to define the specifica-tions for the cranes. Our shared experi-ence on the previous project made it easi-er to establish the important factors and toconcentrate on the essential technicalfeatures. As had been our experience withthe Eltmann project, the new inquiry wasfor a full scope of paper mill cranes. Thelifting capacities were higher, but other-wise called for the same technical solu-tions with high-quality Konecranes compo-nents. The inquiry also included 10 fullyautomated vacuum lifter cranes for paper

Konecranes’ common projects with Palm Papier 1997/1998/2000

At the end of 1997, an inquiry for a project called Hong Kong Paper landed on a table at KCI Konecranes’ offices in

Hyvinkää, Finland. Sent through Konecranes’ sales agent in Germany, the inquiry concerned a new paper mill project.

It was something of a mystery since no one seemed to know anything about a paper mill project in Hong Kong. It

was several months until we learned the real identity of the end customer. The project was actually for Germany’s

Papierfabrik Palm, who was building a new paper mill in Eltmann, Germany.

reel storage (Konecranes Autostore) and acrane for loading the paper rolls ontoships.

Project organisations in close collaboration

In the upcoming months the newpaper mill started to take shape. Jabs &Fischer from Germany were awarded theorder for the building engineering. CTSEngineering Oy, from Finland, was con-tracted for project management and thepaper machine and conveyors wereordered from Finland’s Metso Paper. Ourprior experience working together with allof these partners gave us an excellentopportunity for seamless co-operation,particularly since two of the partners werealso located in Finland.

In early 2001 the technical data for thepaper mill cranes was specified. After sev-eral different layouts, crane alternativesand capacity calculations, the conceptfor the storage had also been optimised.The first phase included five cranes withthe possibility to expand to 10 cranes toensure flexibility for future needs. With thispreparation completed, the negotiationsbetween Palm and Konecranes began.

Once again, Palm chose KCIKonecranes as their crane supplier, andwe reassembled our previous projectgroup. As the size of this project is consid-erably larger our team was reinforced with

a few new members, including a hard-working project engineer and a softwarespecialist to take care of the paper reelstorage automation and storage adminis-tration. The main project management islocated in Finland. Our project manager inGermany handles most of the contactswith the customer and German suppliersand will be later in charge of the erectionand start-up.

Requirements for the crane supplier ona project involving the world’s largestcardboard machine and paper reel stor-age system were, of course, very exacting.Suppliers capable of handling projects ofthis size and complexity are few and farapart. Technical solutions developed dur-ing Konecranes’ decades of involvementwith the paper industry and also duringPalm’s recent Eltmann project haveproven their robustness and reliability.

Due to the enormous size of the paperreel storage, this project created entirelynew crane challenges that required newsolutions. Konecranes totally redesignedthe construction of the hoisting machinery,incorporating features used on cranes inthe waste to energy industry, where dutyrequirements are very high. The vacuumlifter construction was also reviewed. Theredesign reduced the height of the craneby 1 meter, which also reduced the heightof the storage buildings. Five buildings,each 35m wide and 100m long, were low-

ered, reducing the customer’s overallinvestment in storage considerably.

When completed in 2003, this projectwill represent an important paper industryreference for KCI Konecranes. Today, over150 paper machines worldwide are run-ning under cranes designed and built byKCI Konecranes and equipped withKonecranes’ SpaceMaker hoists. We arevery proud that at Papierfabrik Palm’s newfacility, Konecranes’ SpaceMaker will ser-vice the world’s largest paper machine.The paper reel storage ( with KonecranesAutostore System ) is also the world’slargest for this specific paper quality.

The Global Crane Company shares the tasks

As the new mill takes shape, our pro-ject team continues to work closely in Ger-many and Finland to coordinate projectengineering tasks while crane manufactur-ing goes forward in Germany and France.The erection team will involve specialistsfrom the crane factories, software special-ists planning the erection/start-up and ser-vice technicians from Konecranes’ branchoffices near the new mill. Deliveries willstart in November 2001 and continuethrough 2002. ■

Petteri Viinanen, Sales Manager, Kulicke Konecranes GmbH

[email protected]

KONECRANES SUPPLIES CRANESFOR THE WORLD’S LARGESTPAPERBOARD MACHINE

navigation, all of which are available onthe new Jaguar X - TYPE.

Crane refurbishment details

The refurbishment and modernisationof the cranes involved replacing the oldCarruthers open winch doublegirder trolleys with all newKonecranes SM trolleys, replac-ing existing slipring motor con-trol with Konecranes DynAHoistand DynAC drives for trolleyand bridge movements. Com-plete electrical rewire with new festooncables and new electrical control cubi-cles.

The line shaft single motor long traveldrive arrangements are also beingreplaced with twin Konecranes GM dri-ves, utilising existing wheels where theyhave been altered to be of live axledesign.

Two of the cranes have sufferedextensively through poor rail alignmentand hard use over a number of years.Both of these cranes are removed fromthe rails, returned to KONECRANES (UK)factory in East Kilbride near Glasgow,totally stripped of the old end carriagesand drive arrangements and all newKonecranes SH bogeys are being fitted.Prior to the end carriage change, the

achieved through significant investmentin technology and people.

KONECRANES (UK) Ltd. are proud tobe part of this transformation at JaguarCars.

The history of the Halewood plant

The Halewood automotive plant wasoriginally opened by the Ford Motor Com-pany in the early 1960s’ with the first carbeing produced in March 1963. Over theyears, Ford produced models such as theAnglia, Corsair, Cortina, Capri, Zephyr,Zodiac and of course the highly success-ful Ford Escort which was first introducedin 1968. In 1991 Halewood’s 5 millionth

Escort came off the production line. InJuly 2000 the last ever Ford Escort to beproduced at the plant rolled of the pro-

THE STORY BEHIND JAGUAR’S LATEST MODEL

■ 1 x 50t SM0812/5t XL508F5 trolley + DynAHoist V30F + GM10 bridge drives

■ 1 x 30t SM808 trolley + DynAHoist V45F + GM10 bridge drives

■ 2 x 30t SM808 trolleys + DynAHoist V30F + GM10 bridge drives

■ DynAC travel and traverse drives + new electrical control cubicles.

“Jaguar Cars officially inaugurated itsnew 300 million GBP plant today. The new Jaguar X – TYPE goes onsale this week and is to be built at theplant.” Source: Jaguar Cars pressrelease, Date 25th May 2001,Liverpool England. At this dateKONECRANES (UK) had beenworking with Jaguar Cars for over twoyears on this project in the area of therefurbishment and modernisation oftheir cranes.

KONECRANES (UK) and

The launch of the Jaguar X - TYPEcan be seen the single biggeststep in Jaguar’s growth strategy,

accelerating Jaguar’s transformationinto a major competitor in the premi-um car segment.

Jaguar Cars Halewood plant hasproduction capacity of at least100,000 vehicles per annum. The newJaguar X - TYPE is expected to dou-ble Jaguar car sales when it is in fullproduction. During 2001 Jaguar esti-mates to sell across its model range over85,000 cars worldwide.

The cornerstone of the transformationat Jaguar Cars Halewood plant has been

duction line and Jaguar implemented itsmajor plant refurbishment program.

The Cranes at Halewood

Nearly all of the cranes at the Hale-wood plant were built by J.H. Carruthers& Co Ltd, now known as KONECRANES(UK) Ltd. The cranes are mainly of con-ventional double girder construction witha small number of Carruthers Monoboxsingle girder torsion cranes.

Jaguar Cars and KONECRANES (UK)engineers inspected the existing cranes,checking the original design requisite,comparing this with the plants newrequirements for crane operations. This

joint review resulted in specificationsand phased refurbishment andmodernisation proposals being cre-ated for the key cranes to matchthe X -TYPE production build.

The main thrust of KONECRANES(UK) project team’s proposals was togive the old Carruthers cranes astep change in performance, con-trol, safety and reliability to matchthat of the new Jaguar X – TYPEcompared to the models previously

produced at the Halewood plant. How-ever, the new crane features that wereoffered for the cranes did not includeleather seats, cruise control or satellite

offending long travel rails were replacedand re-aligned.

Konecranes SM trolleys, with theadvantage of low dead weight (allowingsome increased capacity whererequired), true vertical lifting, and overallmodern design complete with platforms

for maintenance access,overload protection foradded safety, and the abilityto be customised for JaguarCars without affecting stan-dardisation issues, has provento be the ideal solution.

Konecranes DynAHoist and DynACinverter variable speed drives remove theneed for micro speed control, reducestress in components and structure givingpeak performance with smooth opera-

tion, added safety supervision and main-tenance diagnostics. DynA drive technol-ogy and some new slipring motor controlsare also being employed in some of theother cranes where the hoist machinery isbeing retained.

The design brief on the selection ofequipment was to give the ultimate incrane performance that would see thesecranes operate for many years to come,ensure spares availability and use a com-mon design approach with the samecomponents on more than one crane,thereby reducing the number of spareparts to be held.

The refurbishment project for thecranes at Jaguar Cars is phased well into2002 with the benefits of the refurbishedand modernised crane operationsextending to more of the cranes at theHalewood plant as the new Jaguar X -TYPE approaches full production.

Jaguar Cars orders placed withKONECRANES (UK) for this project nowexceeds EURO 1,370,000. ■

Gordon W. Adie, Managing DirectorKonecranes (UK) Ltd.

[email protected]

For more information visit our web pages

www.konecranes-uk.com

For more information on Jaguar cars visit webpages www.jaguar.com

Konecranes techn ica lso lu t ions fo r t he p ro jec tinc lude the fo l low ing :

Konecranes components now being employedat Jaguar Cars’ Halewood Plant.


MAINTENANCE PROGRAM AIMEDAT KEEPING CRANES ON MOVE


The last thing any resources company needs is costly interruptions toproduction because of breakdowns – or expensive cranes wearing outprematurely because of poor maintenance

Newcrest Mining uses more than adozen cranes, often simultaneous-ly, to ensure quality maintenance

of its production equipment at Cadia,where production will ultimately build upto almost 300,000 ozpa gold and 23,000tpa copper.

Incorporating heavy equipment suchas the largest SAG mill in the world(20MW) and two ball mills rated at almost9,000kW, the extensive infrastructure atCadia has to be serviced comprehensive-ly to tight deadlines during the limitedequipment shutdowns required to main-tain plant in peak condition.

Specialised cranes, ranging from lessthan 1t to more than 100t capacity, arerelied upon in key production areas suchas the sag mill, flotation building, crushersand workshop.

“Cadia has been operational onlysince June 1999, but experience hasshown that crane availability is a highlycritical component in our strategy to gainoptimum output from the mine,” Cadia’sengineering manager Leigh Cox said.

“Cranes are sophisticated units and,because the technology is quiteadvanced, it is difficult to find personnelwith the appropriate engineering exper-tise and familiarity with the broad rangeof equipment employed here.

“We focused on this issue from dayone when evaluating how best to caterfor our crane needs and ultimately chose

“This measurability, or return on invest-ment, is integral to the arrangement withorganisations such as Cadia.

“Our strength in dealing with world-class organisations such as Newcrest Min-ing is that, as a truly world-class organi-saiton ourselves, we are operating at thesame level with the same objectives andsame standards.

“Rather than mine operators dealingwith disparate suppliers with individualfragments of expertise, Konecranes cancontinuously focus international resourcesand expertise through our people onsite.”

Mr Cox said quality of service is partic-ularly important when the cranes areemployed during maintenance shut-downs.

“It is then that crane maintenancequality can be tangibly measured interms of the amount of uptime and relia-bility they offer,” Mr Cox said.

Included under the maintenanceagreement with Konecranes to deliver this

Konecranes installation at the Cadia gold andcopper mine in New South Wales.

KONECRANES MODERNIZESGANTRY CRANE FOR DYCORE OF THE NETHERLANDSDYCORE is one of Holland’s largest producers of standard floor elements, atrade term for the reinforced concrete slabs used in residential and officeconstruction. The company is part of the CRH-Group headquartered in Dublin,Ireland. The floor elements are produced in four locations in the Netherlands.The hollow-core slabs are manufactured at DYCORE’s plant in Oosterhout. Theelements are stored in the outdoor stocking yard where they await transport bytruck to construction sites throughout Holland and Belgium. The stockyardemploys three cranes to facilitate storage and shipping, one of which wasrecently modernised by Konecranes Schippers located in Purmerend,Netherlands.

The three cranes in the stockyardinclude two smaller gantry cranes thathandle small elements and one larger

crane (span 38 m cantilevers 2x 17 m) builtby HMC which handles the bigger ele-ments. This larger crane was modernisedby Konecranes Schipper.

Ton Bogaard, crane specialist atKonecranes Schipper, talks with PeterSnetselaar and Freek Tange of DYCORE,about their experiences working withKonecranes.

When was the crane originally purchasedand for what purpose?

Dycore: The HMC crane was pur-chased in 1979 to handle the very biggestelements the company manufactures. Atthe same time, we changed the logisticsof the yard so that we could load thetrucks under the cantilever of the crane

and have extra storage capacity undercantilevers.

What about capacities?Dycore: At that time we were manu-

facturing 150.000 – 250.000 sqm of floorelements and at present the level is1.100.000 sqm. The HMC crane handles 60– 70 percent of our plant capacity. Weare currently at maximum throughputbecause our production machines are atnearly 100 percent capacity and used inshifts. Our total production will be bit lowerthis year because of the slowing of theeconomy. But we expect that this cranewill continue to handle 60-70 percent ofour output for the next few years.

Peter Snetselaar (on the left) and Freek Tange ofDYCORE, Oosterhout, Netherlands.

reliability are an 80/20t, 38m span girdercrane over the SAG mill; a 10t x 23m spansingle girder crane in the flotation build-ing; a 10t x 14m span single girder cranein the flotation building; a 120t x 6m spandouble girder crane at the primary crush-er; a 20t monorail hoist in the primarycrusher; three 1t x 5m span single girdercranes in the mill lube rooms; a 15t x 5mspan portal crane in the workshop; a 5t X15m span single girder crane in the work-shop; a 30/5t x 10m span semi-portalcrane in the recycle crusher; and a 5tmonorail hoist in the reclaim tunnel.

“During a shutdown, we would havebetween 100-200 contractors working onsite and Konecranes’ technicians blend inas part of our in-house team,” Mr Coxsaid.

“This is important because if any of thecranes stopped in the middle of an oper-ation such as a pump replacement thenit would delay the entire shutdown, andwould equate to a major production loss.

“Because the cost of lost production istoo much of a risk to take, we have theKonecranes’ personnel on standby aspart of the comprehensive service agree-ment.

“Because Konecranes gives Cadia anoutsourced expert service, its personnelworking here are always highly skilled andcarry out tasks expediently,” Mr Cox said.

Mr Yakos said the Cadia serviceagreement integrates Konecranes’ exper-tise with Cadia’s own, to achieve the bestblend of on site and outsourced knowl-edge.

“Konecranes’ personnel not only pro-vide detail service, they keep a constanteye on the broader picture. They arealways alert to any issues of wear devel-oping or anticipated, which is very impor-tant given both the direct investment incranes and the need to avoid downtime.” ■

Mr Edward Yakos, managing Director, Konecraes Pty Ltd Australia,

[email protected]

Konecranes as a preferred supplier,” hesaid.

Using its experience with more than188,000 cranes of all makes under mainte-nance agreements worldwide, Kone-cranes’ maintenance plans are based onthe premise that optimising crane mainte-nance means spending the right amount– neither too much nor too little – to pro-tect ongoing production and to minimisedown time over the optimum lifespan ofeach crane.

Konecranes Australia managing direc-tor, Edward Yakos, said the programsapplied to Cadia’s cranes are designedto go beyond preventive and predictivemaintenance, to a top-tier solution of reli-ability-based maintenance manage-ment.

“While old-style strategies havefocused solely on reducing cost – atworst, fixing things only when they break –Konecranes believes optimised mainte-nance must be able to demonstrate ameasurable return on maintenance dol-lars, in calculations that treat mainte-nance as an investment rather than acost,” Mr Yakos said.

One of Australia’s most successfulgold miners, Newcrest Mining, hasset in place a comprehensive cranemaintenance agreement to helpensure uninterrupted production at thehuge Cadia gold and copper minenear Orange in NSW.

MAINTENANCE PROGRAM AIMEDAT KEEPING CRANES ON MOVE

How important is the crane to your operation?

Dycore: As you can see from the previ-ous answer, it has to handle all of thelonger elements we produce. The othercranes are not able to do that job. Hiringmobile cranes is not an option in a yard ofsome 24.000sqm where order picking fromthe entire yard is done with the crane. Ifthis crane stops, both our production anddelivery will stop as well. This is why thecrane modernization had to be done dur-ing our holiday period, with the craneready to use on the following Mondaymorning at 6.00 a.m. sharp.

What were the main reasons for modernizing this crane?

Dycore: Wearing of the crane wheelsstarted some years ago, but last year thewear became dramatic. We had severalinstances when the crane was at a stand-still while we changed wheels. Just beforethe modernization we installed the lastspare wheels we had and these werenearly worn out within a month. Wheelwearing started at fixed leg side, but lastyear the hinged parts also started to wearseverely. All hinged parts on the craneincluding bogies, sill beams and hingedlegs showed big plays and tolerances. Werealized that ongoing repair would be verycostly and time-consuming.

In addition, the inverter control had tobe replaced because it was an olddesign—unreliable and we were unable toobtain spares. And, in the last six monthsthe motors started to show the effects ofdegeneration. It all added up to a cranethat we could no longer rely on.

What expectations did you have for this modernization?

Dycore: We wanted to solve all theexisting problems with the crane, minimizefuture maintenance costs, and put our-selves into a position to possibly automatethe crane at a later time.

Why was Konecranes Schipper slected to perform the work?

Dycore: A number of elements influ-enced our decision. Konecranes Holland(KCH) the organization behind Kone-cranes Schipper increased our confidencebecause we knew they would back upthe offer. Normally we do all the electricaland software part ourselves, but thenagain the availability of a total solution(electrics and mechanics) from onesource (with guarantees) appealed to us.In addition, we were guaranteed fastdelivery and short down time of the crane,accomplished in part because all dataand drawings and calculations were partof the KCH archive in Rosmalen. One com-peting firm had to combine two offers of amechanical and an electrical subsupplier.Other competitors dealing primarily in har-bour cranes were too big and slow tomeet our deadlines.

What was your experience cooperating with Konecranes Schipper?

Dycore: Looking at the total project it isamazing how fast things went. Initial talkswere going on at the end of Decemberand the final offer came at the end ofFebruary. The scheduling was very verytight. When the project began there was amisunderstanding about whether remount-

ing all the fixed cables on the crane waspart of the original offer. Initially weassumed it was, then learned that this wasnot the case, which caused some distur-bance. Konecranes Schipper then pre-pared a second offer, which coveredremounting of approximately 2 km ofcable. Their performance on siteappeared quiet and professional. Despiteof some last minute deliveries the job wentsmoothly. Aalthough the last weekendwas a really hard-working one for every-one. Our combined efforts forged anexcellent working relationship and we feelthat everyone did a good job.

How do you judge the quality of the materials?

Dycore: Very good, everybody ispleased. The crane works very smoothlyand the crane driver can maneuver downto the last inch. Moreover, accelerationand deceleration are more efficient.Some adjustments are still being made tofine tune the synchro-system. The appear-ance of the new structure is very bright, itlooks very strong and we like the fact thatthe sill beam is high enough to pass under-neath.

Would you order new modernizations from us in future?

Dycore: (laughing) We would like to.This is an important breakthrough withKonecranes products and we will surelyaddress new inquiries to you. ■

Ton Bogaard, Crane Specialist,Konecranes Shippers

[email protected]


Cranes play a critical role in paper-making, continuously removingthe finished paper reels from the

machine, and elsewhere throughout thefinishing and converting process. A milloperating three continuous shifts cannotafford any interruptions in production, soits cranes must be utterly reliable.Because they are also used to maintainthe paper machines, cranes becomeeven more crucial when a paper machinestops running.

“All crane mainte-nance and modernisa-tion must be done whileproduction is underway.This mandates extremecompetence and flexibili-ty on the part of thecompany in charge ofmaintenance and mod-ernisation, which is whywe have worked in closecooperation withKonecranes for a long time,” explains ReijoAhola, automation foreman of the Jäm-sänkoski mill.

The cranes at Jämsänkoski haveundergone continuous modernisation inorder to keep them up to date. Of the tworecently modernised 20-ton PM4 Fiskarscranes dating from1973, only the steelframe remains of the original equipment.

“Modernisation has been the sensibleway to extend the cranes’ life span. Theoperation began in 1992, and now the

cranes function at a level that our produc-tion requires,” Reijo Ahola says.

An independent partnerThe Jämsänkoski paper mill has four

paper machines producing various typesof printing papers. There are always twocranes for each machine at the mill, sothat at least one is available if the other isbeing serviced.

“Our employees have increasinglyconcentrated on thesupervision and controlof the automated paperproduction process. Weneed a partner capableof handling both themaintenance and theongoing modernisation.Konecranes has beenable to offer us the ser-vice we require,” saysAhola. In his view, theprime qualifications for a

partner are speed, reliability and the abili-ty to work independently.

“Konecranes’ technicians work on theirown, allowing us to concentrate fully onour own tasks. Since signing the mainte-nance agreement in 1992, our coopera-tion has intensified – a clear sign that weare satisfied with their service,” Aholaemphasises.

The maintenance agreement ensuresthat UPM-Kymmene is kept informed of thecurrent condition of its cranes and of

upgrades that may be required in thefuture.

“Regular meetings with Konecranesprovide us with projections on the life spanof our cranes and a proposed modernisa-tion schedule. In return, we provide infor-mation on our plans for increasing produc-tion capacity. If we have plans to increasethe capacity of a given paper machine,we can alter the modernisation scheduleand then carry out both tasks simultane-ously.”

In addition to long-range planning,Ahola emphasises the value of day-to-daycollaboration. Konecranes’ techniciansare at the mill almost daily, which helpsthe operation run smoothly.

Demanding modificationsThe maintenance of paper machine

cranes is technically very demanding.Konecranes’ technicians work above therunning paper machine, under conditionsof extreme heat and humidity. Schedulesare tight, and there is no room for error.

“On the two Fiskars EOT (electric over-head travelling) cranes, new long travel-ling machinery and inverter drives wereinstalled by one of Konecranes competi-tors in 1992. In 1995, two new KonecranesXL 608 trolleys custom-tailored to our appli-cation were installed on each crane.These trolleys include automated hook lev-el compensation allowing them to workflawlessly together. The 1995 modernisa-tion also included a new electrical systemwith remote radio controls. In 1997, we dis-covered that the travelling machineryinstalled earlier no longer met our require-ments, we chose Konecranes to mod-ernise the cranes and to replace theinverter drives”.

According to Reijo Ahola, this multi-stage modernisation has been a greatsuccess. It has resulted in totally up-to-date cranes the mill can count on for full-time use in production. Modernisation hasbeen a realistic means of sustaining theusefulness of years-old capital investmentswhile continually adapting them to meetthe needs of a modern paper mill. ■

MODERNIZATION OF PAPER MILL CRANESENSURES UNINTERRUPTED PRODUCTION

The Jämsänkoski and Kaipola paper mills of UPM-Kymmene Corporation,with an annual output of more than 1.4 million tons, are a majorpapermaking source even on an international scale. Cranes are an essentialcomponent for both mills; the Jämsänkoski mill alone has over 100 craneson site.

Automation foreman

Reijo Ahola is pleased with

the Konecranes

partnership, which has

freed mill personnel to do

their own work and ensured

access to the most recent

know-how in crane

technology.

Seppo Juvonen, Sales engineer, Konecranes Nordic Oy

[email protected]

Powerful, Flexible, Modular.The new DynA2002 Seriesrepresents the leading edgeof technology for highperformance crane controls.

DynA2002 drive technolo-gy is now available upto 90 kW, and will soon

be available up to 1500 kW withall of the features required bytoday’s cranes. DynA2002 con-trols are supported by full service engi-neering, manufacturing, and after salestechnology centers on two continents.DynA2002 offers Konecranes’ customers awide range of models optimized for vari-ous uses, which all share the same hard-ware and software architecture. The newDynA2002 platform was designed to servethe broad spectrum of cranes and otherrelated lifting equipment manufacturedby KCI Konecranes throughout the world,and is the most universal crane-specificdrive available.

This new crane control has achieved aperformance level unmatched by anyother product on the market, far beyondwhat can be achieved with general-pur-pose inverters. DynA2002 technology wascreated specifically for enhanced cranesafety and performance, designed tomatch the special requirements of thecranes manufactured today. KCIKonecranes has worldwide experience innot only light-duty cost-effective cranes,but also in heavy-duty industrial processcranes and huge harbour and shipyardcranes. This unique advantage gives KCIKonecranes the core know-how to buildtailored drive solutions for any lifting appli-cation imaginable, worldwide

Crane-specific is a keyword for us.General-purpose inverters used withpumps and fans have neither the safetyfeatures nor the robust power needed tohandle rugged lifting tasks. Instead,Konecranes combines the latest inverter

technology with proprietarysoftware developed byKonecranes to deliver optimallifting performance. The resultis the DynA2002 family of dri-ves with models from 0.75kWto 90kW and soon up to1500kW. The unique demandsof each crane applicationare served through variousoptions available in theDynA2002 range. This includesmodels with both hardwareand software features

optimized for virtually everytype of crane – from light-dutyassembly line cranes to heavy-duty industrial process cranes.

Quality and safety come first.These ideas were at the forefrontof Konecranes’ R & D effort whendesigning the DynA2002 drivefamily. All hoist drives include aSSU (Speed Supervision Unit) safe-ty device designed to preventaccidents by monitoring feed-back from the hoist. This watch-dog technology monitors hoistoverspeed, stall and many otherfeatures related to safe liftingpractices. All DynA2002 drives comeequipped with an internal three-phase lineRF filter to reduce electrical disturbancesand interference with other equipment.

The flexibility and level of modulationof the DynA2002 drive family is unprece-dented in the crane industry. Designed toreduce purchasing and operating costs,the need for spare parts is dramaticallyreduced due to design similarities in thecomplete family of DynA2002 drives. Thecommon control module containing thedrive CPU, SSU, I/O boards, system expan-sion boards, Profibus DP board, and spacefor various options are fully contained with-in a single plug-in module. Replacementcan be performed in less than one minute.

DynA2002 has a new programminginterface with a back-lit LCD display that isextremely user-friendly. It insures quick

commissioning, operation monitoring, andeasy trouble-shooting. A clear step-by-step menu has been created to assistthose who do not use the drive on a dailybasis. If trouble is encountered, help is onlya phone call away from the local supportcenter.

DynA2002’s crane application soft-ware is designed to fit lifting needs world-wide, and respond to the demands ofeach market. Konecranes’ R&D depart-ment bases its designs on customer feed-back and real-world experience. The

structured System Analysis Method isused to write, program and testthe software to provide quality,controlled software solutions.DynA2002’s hardware is basedon the latest inverter designs,ensuring years of serviceability.

The new DynA2002 and itspredecessor the DynA familyof drives are fully supportednot only from our factory in Fin-land but also from our new USSupport Service Center. Bothlocations offer productionoperations, a fully equippedspare part stock, repair, and

training service capabilities.Both locations also provide skilled

personnel for phone and on-site supportfor all DynA and DynA2002 products. ■

Kari Wallgren, Director, Automation and Electrics groupKonecranes Components [email protected]

– SUPERIOR CRANE DRIVE TECHNOLOGYDYNA2002

Electric hoists are used in almost everyindustry for handling loads from hun-dred kilos up to one hundred tons. All

new KCI Konecranes’ wire rope hoists areequipped with Premium system. The dif-ferent models of the Premium range; Per-form, Lifetime, Optic, Multicare and Inter-face offer solutions for every crane appli-cation from light duty industrial cranes upto heavy duty process cranes.

Safety and productivity with Premium Perform

The continuous calculation of theload and the setting of intermediate loadlimits together with overload protectionincrease personnel safety. Premium alsoswitches automatically from fast speed tolow speed when the loading increasesrapidly. If an overload situation occurs,Premium stops the hoisting but allows low-ering of the load. Load positioning ismade faster and easier with smoothspeed changes. This reduces wear andmechanical stresses on equipment. Inhigh temperature environments andexceptional peak usage situations addi-tional performance guarantee is providedby constant temperature control andthermal protection of the hoisting motor.

Optimised service and reliability

Premium Lifetime has versatile measur-ing and calculation functions for monitor-ing the actual usage and condition of thehoist. Thanks to the information gatheredand calculated by Premium it is easier toplan and schedule the maintenance pro-cedures. This saves money and is an addi-tional guarantee for maximal uptime. The

remaining safe working period andremaining service life of the hoisting brakelining, actual hoisting motor temperatureand faults recorded. Automatic warningsindicating an exceeding of design limitsare displayed as well. This enhances safe-ty, more effective maintenance and per-formance.

Premium Multicare – benefits for cranes with several hoist

If there are several hoists on thecrane, you can control all of them withPremium Multicare. It continuously moni-tors the accumulate load handled byeach hoist, which is vital if the capacity of

Premium is KCI Konecranes’ newsystem for hoist and crane safety andperformance control. The system isbased on modern electronics andsoftware design. Premium makeshandling of heavy loads safer andeasier. It is also used to optimisemaintenance and to enhanceperformance.


HIGHER CRANESAFETY AND BETTERPERFORMANCECONTROL

monitoring of the remaining Safe WorkingPeriod is automatic and precise. Thefuture modernisations can be plannedeasier and without unnecessary safetymargins in calculations.

Premium Optic keeps you informed

The crane user can at any momentcheck the usage and condition of thecrane without climbing up to the crane.The pendant controller is equipped with adigital display showing e.g. total runningtime, number of starts and hoisting cycles,

the crane is less than the lifting capacityof the individual hoists counted together.The operator can also read and receivethe information from each hoist from anypendant controller equipped with Premi-um Optic display.

High flexibility for the modern world with Premium Interface

Data exchange with PC or PLC is pos-sible via serial RS232 data interface. Thisoffers interfacing with high level automa-tion systems as well as advanced mainte-nance management systems. ■

Profile grinding is a method that finish-es gears and pinions with a profiledgrinding wheel instead of a wheel

with straight flanks. The conventional orold-style method forms the profile of agear tooth by combining cross and rota-tive movements of the machining tablewith the grinding stroke. In this newmethod a precisely profiled abrasivewheel cuts the whole space between twoteeth in a single movement. This shortensmachining time and enables theKonecranes Gear Factory to producegears of extreme quality and precision.

This method is actually new only forthe process of manufacturing small andmedium-sized gear lots. The auto industryused similar special tools for mass produc-tion long before gear productionbecame computerized. But manufactur-ing smaller numbers of one-design partscalls for tooling and fixtures with versatility.Now, increased computing capacity

GEAR FACTORY BEGINS PROFILEGRINDING OF GEAR WHEELSKonecranes Components Corp. hasrecently made a substantialinvestment in the latest gear grindingtechnology with the installation of twonew profile grinding machinespurchased and commissioned during2000 and 2001.

How can we at KonecranesComponents Corp, as a corporationmeet the ever-changing demands ofour customers? How can we developthe customer relation in acomprehensive way and continue toprovide the right added values, whichwill retain the trust of the customerand produce positive experiences?The answer is: by listening to thecustomer

Continuous Measuring of Customer Satisfaction

We, at Konecranes ComponentsCorp, have paid careful attention to mat-ters of customer satisfaction and handledcustomer feedback for many years.Based on this experience we have devel-oped a new Continuous MeasuringProcess of Customer Satisfaction to listento and to learn from our customers. Thecorporation poses several questions toitself about what has been done right,where there is room for development andif there are any unnecessary phases in itsbusiness processes. On the basis of feed-back main areas of development will beaddressed, concrete measures forimprovements will be taken, new opera-tion plans for individual customers and forthe whole organisation will be set.

Positive customer feedback on a jobwell done is also useful and helps to iden-tify and maintain the strengths.

The goal of our survey is to monitorthrough an on-going process customers’satisfaction towards our products and ser-vices in order to develop them to bettermeet their needs and requirements. Cus-

Caring for and listening to our customers

at KONECRANES COMPONENTS CORPORATION

NEW CUSTOMER SATISFACTION SURVEY

tomer satisfaction must be brought to alevel where it has a positive effect on cus-tomer commitment and loyalty. The surveyexplains the most effective ways to influ-ence customer loyalty and identifies themost essential areas of development with-in our organisation to strengthen it.

Our Customer Satisfaction Survey stud-ies both the end customer as well as otherparticipants in the sales process, such asthe sales manager and supervisors, as theiropinion is also valuable to us.

The survey is divided into five sections,each containing several questions andclaims. The customer is asked to estimateto what extent he agrees with certainclaims and to express his level of satisfac-tion to the operations and to rate theirimportance to his own business.

In our survey sheet there are questionsregarding the different stages in the deliv-ery process, such as product features, thedelivery itself, customer service and com-petitor comparison. The analysis tool is

based on an importance and perfor-mance grid, which indicates where toconcentrate. The follow-up provides valu-able information of different trends duringthe months and years. The results of theSurveys are reviewed and handled twicea year in the Konecranes Components’Management Review meetings.

Customer Satisfaction Survey – as part of the Quality Standard

The Customer Satisfaction Survey hasbeen developed to meet with the require-ments of the ISO 9001:2000 Quality Stan-dard. Alike excellent product quality, thequality of customer satisfaction is one ofour areas of top priority. ■

Maarit Pentti,Sales Assistant,Konecranes Components [email protected]

makes it possible to construct a machineable to calculate the given geometry ofeach individual gear,and dress or profilethe grinding wheel accordingly. This geo-metric programming is needed not onlyfor every single gear manufactured, butalso for every single cut because of theprecision required. Sophisticated softwareallows the new machines to perform thesefunctions automatically.

Konecranes Components ordered thegrinders for the Gear Factory after a thor-ough evaluation of technologies andmodels available from different manufac-

turers. As a result, we selected the 400 mmPfauter PG400 grinder for shaft production.For gear wheels,the Oerlikon OPAL 120machine with 1200 mm maximum diame-ter was chosen.

All of us at the Gear Factory are work-ing hard to get the most out of our newmachines in order to manufacture still bet-ter, longer-lasting and even more com-petitive gear reducers for our crane cus-tomers worldwide. ■

Tuomo Glad, Manager, Gear FactoryKonecranes Components Corp.

[email protected]

The sales team at Hyvinkää, from left Seppo Tujula, Kaarlo Veräväinen, Jorma Marjanen, TimoParkkari, Kaarlo Martinkauppi, Taisto Järvinen, Hannu Piispanen, Tapani Erkkilä, Juha-Matti Jerkku,Maarit Pentti, Harri Ahonen, Hannu Tossava.

Sales by Business Area*

* Including internal sales

Total Sales 703.0 MEUR

Special Cranes189.6 MEUR

24 %Maintenance

Services342.0 MEUR

44 %

Equipment253.4 MEUR

LiftingStandard

32 %

EU

(excl. Nordic)

200.9 MEUR

29 %

Asia-Pacific

61.1 MEUR

9 %

Americas

284.4 MEUR

40 %Nordic and

Central Europe

156.6 MEUR

22 %

Sales* by Market

OEMCrane

Builders 5 %

Others 10 %

Pulp and Paper 9 %

PowerPlants 7 %Steel and

otherware-

housing 3 %

GeneralManufacturing

22 %

RefuseHandling 1 %

Automotive 4 %

PrimaryMetals 11 %

Harbours andShipyards 12 %

Resellers10 %

Petrochemical 4 %

Construction 2 %

Sales by Industry

SpecialCranes15 %

StandardLifting

Equipment26 %

Group Staff3 %

Personnel By Business Area

MaintenanceServices56 %

Results 2000


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