the happy customerAND OTHER SHORT STORIES FROM 2011
The Happy CustomerOnce upon a time, there was a steel plant. Inside the plant thewarm air was heavy with the sounds of industrial production.Machines and workers labored beneath a curtain of grime. Fromthe shadows a huge ladle crane slowly lifted its massive load ofscrap metal to the electric arc furnace. A crushing roar and flashof power transformed the scrap into an orange-hot broth of moltensteel. The workers knew that without the service of the monstrousladle crane, the entire facility would come to a standstill.One frightful winter night, cold and blustery outside, hot andloud inside, the ladle crane was crippled by the failure of acomponent in its operating machinery. Over several months themaintenance provider had kept things running but had beenunable to make a long-term fix to a recurring problem. Theoperations manager had recently heard about Konecranes andeasily made online contact with the local service branch using amobile smart phone.Two days later the plant was in high spirits. Konecranes hadresponded quickly, then diagnosed and fixed the problem. Overthe next several weeks Konecranes performed a variety of servicework and offered a number of productivity-enhancing upgrades onthe ladle crane and other lifting equipment.Two months later the customer agreed to a long-term inspectionand maintenance contract. Gradually things began to change.Within one year, unplanned downtime had dropped 40%. Fewersafety-related incidents occurred each month. The companybecame more profitable and invested in additional upgrades thatKonecranes had recommended during their Business Review.Two years later, a second ladle crane is on order. The plant’smaintenance area has two workstation lifting systems.The original ladle crane is running much more reliably afterKonecranes used RailQ and CRS to uncover some problems thatwere not previously known.The customer is very happy.The End.(Note to reader … this story is fictitious, but could be perfectly real. All ofthe other stories in this booklet are actual events and real customers.)
Mission Table of contentsNOT JUST LIFTING AEROSPACE Teledyne Technologies, Inc................ 7 INTERMODAL Union Pacific Railroad..................... 33THINGS, BUT ENTIRE NASA’s Glenn Research Center.......... 8 A Leading Aerostructure A Midwest Locomotive Shop............ 34BUSINESSES Manufacturer.............................. 10 MINING An Underground Mining Equipment ALTERNATIVE ENERGY Manufacturer.............................. 37 Brithinee Electric............................ 11 A Mining Machinery Company.......... 38 Resort Municipality of Whistler........ 12 A Mining Equipment Manufacturer..... 39Vision A Leading Mining Manufacturer....... 40 AUTOMOTIVE“We know in real time how millions of lifting A Midwest Diesel Engine OFFSHOREdevices and machine tools perform. We use Manufacturer.............................. 15 Elevating Boats, LLC....................... 43 A Weld Tool Center.......................... 16 National Oilwell Varco..................... 44this knowledge around the clock to make our A Southern Manufacturing GENERAL MANUFACTURINGcustomers’ operations safer and more productive.” Bauer Manufacturing, Inc................ 17 Company.................................... 46 Link-Belt Construction Equipment POWER Company, Inc.............................. 18 BC Hydro, Mica Generating Station.... 48 A Leading Construction Equipment R.E. Ginna Nuclear Power Plant....... 50Values Manufacturer.............................. 19Trust in People U.S. Concrete................................. 20 PULP & PAPER Liberty Paper, Inc............................ 54We want to be known for our great people. A Leading Construction Equipment Manufacturer.............................. 21 Weyerhaeuser Paper Mill................. 56 Alaskan Copper & Brass................. 22 STEELTotal Service Commitment Novelis........................................... 24 An Integrated Steel Plant................ 59We want to be known for always keeping An Integrated Aluminum Facility....... 25 Westfield Industries........................ 26 Johannessen Trading Company....... 60 A Leading Steel Company................ 61our promises. Limbach Company.......................... 28 EMJ Metals.................................... 62 HARBORS & SHIPYARDS A Leading Steel Manufacturer......... 64Sustained Profitability APM Terminals................................ 30 A Steel Manufacturing Plant............ 66We want to be known as a financiallysound company.Strategies> Differentiation through service and technology innovation> Lifting people> Global footprint and supply chain> Dual-channel For the most current customer stories, go to> Real-time information www.konecranesamericas.com/ customerstories
7Teledyne Technologies, Inc., Huntsville, Ala.KNOWLEDGE, commitment AND Reliabilityincrease uptime AND minimize costchallengeRelocation and repairsAlabama-based Teledyne specializesin full-spectrum engineering andadvanced manufacturing. It operatesin the complex and demandingindustries of aerospace, missiledefense and nuclear energy, servingboth government-supporting andcommercial customers.When faced with a large relocationand repair project, Teledyne Director of Manufacturing Operations, JeffHolley knew just who to call. “I needed a service partner who could facethe challenge, keep the delivery schedule and be capable of handlingcomplex machinery and hardware,“ Holley recalled.SOLUTIONExpert knowledge of complex partsThe scope of the project included the relocation and repair of small-, medium-and large-sized machines with very sophisticated parts, such as highly precise5-axis CNC machines. A team of 10-12 Konecranes Machine tool Service (MTS)engineers and specialists was responsible for the three-month relocationproject including, but not limited to, new foundations, modernization, materialhandling, machine installation, debug, alignments and laser calibration.Due to the complexity of the parts and the special materials and processesused in the Teledyne products, skilled Konecranes personnel wereessential in completing this project.RESULTSCompleted on time and within budgetAs a result of proper planning and effective project execution, therelocation and repair project was completed within budget and one weekahead of schedule. Teledyne and Konecranes MTS are currently discussingexpanding the cooperation between the two companies. Konecranes MTSKey Account Manager Harold Schoch explains, “We simply want to beviewed as indispensable to our customers’ success.” “There were no surprises. MTS clearly understands the needs of our machines and gives a complete analysis and detailed cost estimate.”
8 9 NASA’s Glenn Research Center, Sandusky, Ohio UNIQUE CUSTOMIZATION SAVES CUSTOMER TIME AND MONEY AN ARRAY OF CHALLENGES The original crane system was limited in its ability to provide accurate and A variety OF SOLUTIONS precise movements, and had no way to detect whether a load was too Outer space environment simulation heavy or still bolted to a test fixture. This challenge was overcome with the chamber imposes harsh demands retrofit of a load measuring device integrated with the crane controls. on earth-bound metal, lubrication Because of the sheer size of the spacecraft components being and wiring. suspended for testing, NASA’s engineering team was keen to gain At NASA’s Glenn Research Center precise control in making critical positioning adjustments—a function the Plum Brook Station in Sandusky, 1960s technology did not provide. Therefore, Konecranes recommended Ohio, the Space Power Facility (SPF) variable frequency drives, plus enhancements to provide both inching and is home to the world’s largest space microspeed functions. environment simulation chamber – 100 feet in diameter by 122 feet RESULTS high. The dome-capped vacuum chamber is used to test large, space- Advanced technology from Konecranes saves time, bound hardware within a simulated environment of outer space. enhances safety and improves critical positioning. Selection of new materials and technologies, combined with clever To hoist, position and stabilize spacecraft components prior to testing, engineering design, saved this important customer time and money, while the test chamber is outfitted with a modified polar crane, with the bridge improving safety and functionality. spanning the radius of the area similar to the hands on a clock. Originally built from state-of-the-art systems, controls and materials, numerous upgrades became necessary after nearly 40 years of use. The extreme negative pressure in the vacuum chamber causes outgassing, a condition where compositional molecules, including dirt, oil and grease, are released from substances present in the vacuum environment. These molecules can stick to the surfaces of spacecraft, which must be kept meticulously clean. The crane is constructed of aluminum, which has very low outgassing properties. Outgassing also affects bearings, wiring and insulation in the control panels, all of which require special materials. With typical control panel wiring, every time NASA readied the chamber for a vacuum test they would need to remove the entire control panel from the crane—which weighs several thousand pounds. Instead, Konecranes engineers used Teflon® wire, allowing the majority of the controls to remain in place during simulation events. Certain elements within the control panel, including the inverters, were designed to be removable prior to initiating a vacuum test. Previously, it would take up to several days to remove components with outgassing properties, whereas this new system was designed to enable their removal in a matter of hours.
10 11 A Leading Aerostructure Manufacturer Brithinee Electric, Colton, Calif. Konecranes MTs diagnosed and INCREASED CRANE CAPACITY fixed a long-standing problem, HELPS FACILITY MEET DEMANDS reducing processing time by 60% OF ALTERNATIVE ENERGY and saving $300k per year challenge CHALLENGE Increased demand, Too much scrap more cranes needed A leading global manufacturer Brithinee Electric in Colton, California of aerostructures, located in the specializes in the repair of industrial southern United States, builds electric motors and wind generators. aircraft components such as They needed additional space and stringers, ribs and spars for the increased crane capacity to work on aerospace industry. the large electrical units used in the wind industry, their fastest growing Before Konecranes Machine Tool market segment. Brithinee Electric is Service (MTS) was contacted, an within 125 miles of two of the largest wind farms in the United States. With old but critical machine in the facility produced an unacceptable quantity of demand for alternative energy increasing, the company needed to expand scrap parts, thereby wasting costly raw materials and valuable processing to be able to meet the demand. time. Scrap from the machine in question totaled $300,000 the previous year and $160,000 year-to-date. In 2004, Brithinee Electric began planning an expansion of their workspace by almost 20,000 square feet. SOLUTION Upgrade controls, motors and drives SOLUTION For over a year and a half, the maintenance department and the original Konecranes identifies crane needs equipment manufacture could not determine what was causing the scrap Brithinee Electric’s crane selection involved acquiring dimensions for parts to be created. Konecranes MTS was able to properly identify the machines they had never seen, including overall dimensions as well as problem during the initial visit. weight. Konecranes helped steer the selection based on cranes generally used in manufacturing plants in the wind industry. Because Konecranes MTS Service Engineers had proven themselves with a fast response time to a service need, they were awarded a Konecranes developed several different concepts and layouts for Brithinee modernization through retrofit. Konecranes compared the machine‘s Electric’s new facility. The two companies and the project engineer worked current performance against matching statistics when it was new, together to determine the best solution for Brithinee Electric’s needs, uncovering an unfavorable variance. including how the geometry of the cranes’ structures (bridge length, dimensions between uprights, etc.) would affect price. Based on the results of this assessment, Konecranes MTS proposed an upgrade with new CNC controls, motors and drives via retrofit. After several collaborative revisions to the plan, Konecranes ended up installing a 20-ton crane, a 10-ton crane, a 5-ton bridge crane and a jib crane. RESULTS Less scrap and 60% reduction in processing time RESULTS The Konecranes MTS team has become essential to helping the facility Production levels doubled with new cranes manufacture quality parts and reduce processing time. Konecranes The larger facility and the new cranes have allowed Brithinee Electric to MTS reduced the processing time for some of the components by 60%. double its production of wind generator and large motor repair. Konecranes In a competitive bid process, the aerostructure manufacturer awarded also continues to provide service to Brithinee Electric’s cranes, ensuring Konecranes MTS a gantry mill retrofit project. increased uptime. “The new building delivered a WOW FACTOR, AND THE CRANES ARE A KEY INGREDIENT OF THAT.” Wallace P. Brithinee, Brithinee Electric
12 13 Resort Municipality of Whistler, BC, Canada TURNING MUNICIPAL GARBAGE INTO MARKETABLE COMPOST WITH an OVERHEAD CRANE challenge weigh each load it picked up, which Electric overhead crane needed to move and load compost helped standardize the product. The Resort Municipality of Whistler is a community of 14,000 permanent According to Patrick Mulholland, residents whose Whistler 2020 vision for environmental sustainability is Compost Operations Manager at one of the most aggressive in North America. Whistler annually welcomes Whistler, another good decision was around 2 million guests for winter and summer sports, but due to terrain to let Konecranes Service maintain limitations and a plentiful bear population that rule out a landfill, options the crane with quarterly maintenance for nearby waste disposal are limited. inspections with a heavy emphasis on With exporting its garbage to the state of Washington as the only alternative, preventive measures. “The crane is a Whistler committed to build a new $14 million regional composting facility. sophisticated piece of machinery. We Since a prior composting pilot project at a nearby industrial park in Squamish were happy to let Konecranes take resulted in an odor issue, all planning parties agreed that the material care of the crane so that we could focus on other parts of the process.” handling methods for the new facility would need to evolve. RESULTS One of the major issues identified in the Squamish pilot project was the Composting facility receives clear return on investment front-end loaders burning fossil fuel, which resulted in fumes and exhaust Whistler has begun to get a clear picture of their return on investment in inside the building. They also tended to track biosolid residue all over the the regional composting facility and the crane. The crane reliability has site, creating a very dirty environment. Therefore, a decision was made to been extremely important to the project. replace them with an overhead crane to move and assemble the primary ingredients for compost. “Without the crane functioning, the plant does not function. Without the plant functioning, our ability to deal with biosolids locally comes to a In addition to sustainability, the crane criteria included best possible complete halt. We have the capacity to receive biosolids for only two to reliability, proven technology and the ability to call in local service contacts three days before we have to ship it to Washington State at a significant in case something went wrong. cost,” says Ron Sander, Whistler Environmental Operations Manager. SOLUTION The benefits of the overhead crane have also included the elimination of Five-tonne bucket, 2.5 m3 grab, DynAPilot anti-sway and automation diesel fumes in buildings and confined areas, allowing doors to be kept Based on Konecranes recommendation from Konecranes, a five metric ton closed and thereby minimizing the escape of odors and dust. bucket crane, operated by electricity, was selected for biosolids handling. “Whistler is very pleased about the short and long-term benefits our new The 18-meter operating span with a 2.5 cubic meter hydraulic grab was composter brings,” says Whistler’s Mayor Ken Melamed. “Composting suitable for a small-scale facility and allowed efficient use of floor space reduces export waste, treats multiple waste streams locally, produces and easy access to all stored materials. revenue-generating by-products and saves money for the taxpayers and The crane is radio controlled and equipped with DynAPilot anti-sway load local businesses. The question is why we did wait so long?” control software. It was set up for future automation, though it was decided to have a human running the process, allowing the mixture to be tweaked for changing temperature conditions and pick out unwanted items to maintain quality control in the compost. The crane also had the ability to “There were reservations from experienced operators on the design of using a crane rather than loaders. Now, we’re in agreement that it has been probably the most pleasant surprise of the project – just how well that crane has worked.” Ron Sander, Whistler Environmental Operations Manager
15A Midwest Diesel Engine ManufacturerCUT ANNUAL equipment costsin half with scheduled inspectionschallengeProduction demandsexceeded capabilitiesA Midwest diesel enginemanufacturing plant manufacturesdiesel engines for consumer pickuptrucks. Due to the competitive natureof the diesel engine industry, thecompany is constantly looking to allareas of production to cut costs andincrease efficiencies.The manufacturing plant was constructed in 1971. It originally builtcomponents such as pistons, connecting rods, pulleys, rocker housingsand water pumps. In the early ’90s, the plant was converted to an engineproduction plant. Production demands have escalated ever since.Like other plants of its kind, it is producing numbers well beyond theplant’s original capacity. Therefore, downtime is not an option.SOLUTIONA planned approach to repairs, replacements and spare partsThis Midwest diesel engine manufacturing plant has long focused on theircore competency–building engines. They have relied on Konecranes totake care of their 120 hoists and cranes for over 15 years. In an effortto extend the life of the plant’s overhead lifting equipment, Konecranesidentified the highest usage cranes and set up a maintenance plan forthe cranes selected.The plan included replacing out-dated equipment, rebuilding older “work-horse” hoists and establishing a structure for repairs. This allowedfor repairs to be completed as they were identified during inspections,eliminating potential downtime from unexpected breakdowns.RESULTSPer unit cost decreased 50%, excellent safety recordBy collaborating with Konecranes and sharing expertise, the annual costper unit has decreased 50% from 2005-2009 with no additional downtime.Since this maintenance plan has been put into effect, there have not beenany crane-related injuries or incidents at this manufacturing plant.
16 17 A Weld Tool Center Bauer Manufacturing, Inc., Conroe, Texas Comprehensive preventive maintenance Customized and reliable produCt plan puts customer at ease design puts Customer at ease CHALLENGE challenge In-house maintenance Growing company unable to meet demand requires more cranes In the Midwest, a weld tool center Bauer Manufacturing, Inc. is an for a major automobile company international provider of services, engineers the robotic weld tools that machinery and ancillary products in assemble the body structure of a the earth-working and groundwater vehicle. Over 200 cranes are used at fields, operating under three industry this facility, from 1-ton chain hoists segments including construction, to 50-ton cranes, as well as jib and equipment and resources. gantry cranes. Based in Germany, this 200 year-old The in-house maintenance team was overwhelmed with the crane service company expanded to North America in 2008. Bauer’s first manufacturing needs of the facility. Because service and repairs were not performed headquarters in North America is located in the Conroe Industrial Park in consistently, the maintenance records were not kept up-to-date. The weld Conroe, Texas. The campus sits on 80 acres and is being built in phases. tool center needed a company capable of providing service and preventive The first phase is over 200,000 square feet. When Bauer started maintenance for all of their cranes. to design and build phase one, they turned to Konecranes for their SOLUTION overhead lifting needs. Maintenance outsourced to Konecranes SOLUTION Out of several competing offers, Konecranes stood out as the clear Konecranes provides specialty lifting equipment choice to be the sole provider for crane maintenance. The company has Konecranes was chosen as the provider of Bauer’s eight overhead cranes outsourced 100% of their crane work to Konecranes. The cranes have and two Rubber Tire Gantry cranes. Konecranes offers state-of-the- been repaired and now are performing up to standard. Quarterly and art, high quality products at competitive prices. Because of their price annual inspections help to proactively determine problems before they competitiveness and their follow up with sales and service, they were happen, and monthly preventive maintenance helps keep the cranes in awarded the job. top condition. Bauer had specific needs for the use of the cranes. Konecranes was able A technician is on site five days a week to do repairs and cover to work with upper management to design cranes that would fit their needs. breakdowns. With a strong maintenance team to depend on, the in-house maintenance team no longer needs to track crane inspections, repairs, RESULTS breakdowns or expenditures. Quality products and service satisfy the customer Bauer Manufacturing is very pleased with Konecranes and the sales and RESULTS service team. With the expansion of Bauer Manufacturing in North America, Konecranes Circle of Compliance in place, there are plans to install many more Konecranes products in other facilities satisfied customer purchased eight more cranes in the near future. The customer continues to follow the business plan and benefit from the Circle of Compliance – to inspect, repair and maintain. “We feel comfortable that our Konecranes cranes Based on the successful relationship between the companies, a sister will give us good service well into the future.” plant recently purchased eight new cranes from Konecranes. Bauer Manufacturing
18 19 Link-Belt Construction Equipment Company, Inc., Lexington, Ky. A Leading Construction Equipment Manufacturer Deep expertise results Remanufactured Machine in a win-win situation Increases Uptime and Productivity CHALLENGE while Enhancing Safety Increased production levels CHALLENGE call for machine upgrades and Increased demand called for a new machine modernizations A leading construction equipment manufacturer produces parts and The Link-Belt Construction Equipment components for construction and power generating equipment. Their Company is a leader in the design, production process requires special machine tools for facing pockets. manufacture and sales of telescopic These “pocket facing” machine tools are used to cut the smooth, flat and lattice boom cranes. Their surfaces where the bearings for planetary gears are mounted. Market headquarters are in Lexington, Ky. demand increased beyond the capacity of their critical path machine Link-Belt’s core production base and center for worldwide operations is its tools. They sought a qualified machine tool service team to identify a used 500,000 sq. ft. manufacturing facility. machine tool that could be redesigned and modified to produce the proper part accuracies and finishes required for pocket facing applications. To support their expansion plans over the last 10 years, Link-Belt brought in Konecranes Machine Tool Service (MTS) to provide technical assistance SOLUTION and expertise to solve their machine challenges. A refurbished machine met the challenge With the experience of rebuilding, remanufacturing and retrofitting over 170 SOLUTION machine tools for this construction equipment manufacturer, Konecranes Modernizations performed on diverse machines Machine Tool Service (MTS) had the technical expertise necessary for the In years past, Konecranes MTS had provided many solutions to Link- project. After a careful review and thorough inspection, a used vertical Belt’s machine challenges. Their large Cincinnati-Gilbert Floor Mills were machine with a pallet changer was chosen. The pallet changer reduced mechanically overhauled and retrofitted with a Fanuc control system. “The overall set-up time as parts could be put on the fixture of one pallet while personal delivery of the Mitsubishi special head spindle was appreciated. the machine was cutting a different part on another pallet. You felt this urgency as if you were in my shoes here,” said Bowman to Harold Schoch, Key Account Manager of Konecranes MTS. A customized head was added to generate the pocket facing cuts. Due to the fixture height and the size of the generating heads required for Konecranes MTS performed a complete geometry overhaul of a Giddings the part, a riser was designed and installed underneath the machine’s & Lewis 60, the full contouring table rebuild of a Cincinnati T-40 HBM and column in order to provide enough height for machining the part. The gib the complete restructure of the long “X” axis on a smaller Cincinnati-Gilbert and clamping system of the machine was re-engineered to increase the boring mill as well. machine’s strength, dampen vibrations and make it easier to perform “Your help with our Cincinnati-Milacron, the recent help with the double maintenance work. gantry boring mill head, the Giddings & Lewis 60 and the Wotan Cutmax 2 A new chip collection and conveyor system with guarding was installed to have proven to Link-Belt Senior Management that your staff can work on protect the machine and further reduce the overall maintenance needs diversified machining equipment without concern,” Bowman commented. for the machine. A full enclosure that included door safety interlocks, that RESULTS was not incorporated on the original machines, was designed to further Completed on time and within budget enhance operator safety. “Konecranes MTS continued commitment to quality, attention to meeting RESULTS the customer’s deadlines and coming in on budget continues to make your Enhanced part accuracies, safety and productivity company the first in mind when support is needed on our machine tools,” The machine run off tests showed that the remanufactured machine was continued Bowan. capable of providing the part accuracies and finishes required for pocket facing applications while enhancing safety and productivity. “This Cincinnati-Gilbert machine has worked well for us and was an example of your team’s expertise.” Link-Belt Construction Equipment Company, Inc.
20 21 U.S. Concrete, San Diego, Calif. A Leading Construction Equipment Manufacturer Customized installation, Quality parts and precise deCreased ConstruCtion engineering eliminate downtime Costs and inCreased CapaCity CHALLENGE challenge Quality and productivity Designing a new facility In the Midwest, a leading construction U.S. Concrete serves the construction equipment manufacturer produces industry with concrete and precast/ medium speed diesel engines for prestressed concrete products. electric power, locomotive and industrial applications. As an As a satisfied customer of Konecranes for integral part of the manufacturing over 10 years, there was no question whom process, machine tools are used they would turn to when they were building to bore holes and provide smooth a new plant. “We wanted a design that was finishes to the engines. efficient, well laid out, on time, and of course offered value overall,“ said Todd Ebbert of One of their critical machine tools contained outdated controls, motors U.S. Concrete. “Before we settled on this new and drive amplifiers. The aged components caused control-related failures facility, we looked at different options at existing sites and Konecranes helped that stalled production at the facility. Every moment the critical machine us design and configure various options for each one.” remained out of service cost the facility expensive amounts of downtime. The machine needed to be updated with more reliable components in order SOLUTION to meet projected demands. Customized cranes and layout assistance The new facility would be built on an 18-acre site. The precast concrete SOLUTION manufacturing would be performed in an 80,000 sq. ft. building. The facility Collaborative repairs with the OEM was designed for two large crane bays. These crane bays would be served by A collaborative effort was needed to ensure the best results in the shortest 10 total overhead bridge cranes with capacities ranging from 5- to 50-ton. amount of time. The construction equipment manufacturer needed a supplier with a comprehensive range of technical experience that could effectively It was a concern that the building walls would not be able to support the work in concert with the original equipment manufacturer (OEM) and the in- largest crane’s full capacity of 50-ton. Konecranes suggested that the center house repair team to make the necessary repairs and improvements. 40’ span of the 80’ bridge crane would lift the full capacity of 50-ton while the outer 20’ of the span to either side would be limited to 30-ton capacity. Konecranes Machine Tool Service (MTS) was selected due to their unique This effectively reduced the load on the walls, and in addition, decreased skill sets and access to a comprehensive supply chain for spare parts. construction costs. Konecranes provided technical support as well as Konecranes MTS calibration technicians were able to optimize the machine’s innovative ideas to keep the project cost-effective while meeting all of the geometry and positioning using Hamar and Renishaw laser systems. customer‘s needs. Two cranes from the old facility were brought to the new RESULTS site. Konecranes modified these cranes to meet the new facility requirements. Downtime brought under control, quality increased RESULTS Konecranes MTS Service Engineers eliminated the downtime caused by the Customer pleased with crane system and performance aged machine tool components. The mechanical and geometrical repairs The facility as well as the crane runway system were built to schedule and that Konecranes MTS made increased the quality of parts the facility completed from start to finish in less than a year. “The crane system has produces. The collaborative effort with the in-house repair team and the performed exactly as expected and we are very pleased with the results. OEM decreased the amount of time required for the machine to be put back We have converted a couple of the cranes to wireless pendants and may into production. Based on the success of this project, Konecranes MTS will convert all of them in the near future,” said Ebbert. continue to work alongside the customer on all future shutdown projects. “Our long term relationship with Konecranes has benefitted us with the latest advances in technological and safety aspects for our lifting requirements.’’ Todd Ebbert of U.S. Concrete
22 Alaskan Copper & Brass, Kent, Wash. KONECRANES CXT CRANES AND MAINMAN® INSPECTIONS REDUCE MAINTENANCE COSTS BY 60% CHALLENGE a month on a regular schedule. A Taking old cranes to a new location parallel program for inspecting the Alaskan Copper & Brass Co. was under-hook devices has also been moving a large part of its operation implemented. Konecranes takes from Seattle and Renton to a care of significant repairs, while facility in Kent, Wash. The company minor issues are handled in-house. needed new lifting equipment and “In the first year, we spent a good also wanted to relocate some bit of money resolving long-term older cranes at the Renton facility, problems with the older cranes, but not purchased from Konecranes. since then our maintenance costs Alaskan Copper owned a total of 138 have gone down by around 60%,” cranes as well as about 50 different types of under-hook devices. Most of says Eagle Hilton. “The biggest them were being maintained in a reactive mode, with repairs occurring only benefit is that downtime, and when something stopped working. significant breakdowns have been SOLUTION drastically reduced. Now, we prefer Some cranes relocated, others purchased to maintain equipment at more new, all maintained with MAINMAN® optimum levels. With our new policy In Phase I of this operation, Alaskan Copper purchased two 5-ton single- of outsourcing of maintenance for girder CXT cranes from Konecranes and asked Konecranes to remove four critical equipment like forklifts and older cranes from the Renton facility, modify them and move them to Kent. cranes, we’re down to one in-house This process went well, and Eagle Hilton, Alaskan Copper’s new mechanical electrician at this facility.” project coordinator, retained Konecranes to begin monthly inspections of all of its cranes using MAINMAN®, a multi-point visual inspection. “We are truly satisfied with every aspect of service MAINMAN® inspection captures data on the condition of over 225 crane we’ve received from Konecranes. Companies like yours components and then analyzes, prioritizes and schedules required repairs make companies like ours better and stronger, not to in compliance with local statutes and laws. mention making my job a lot easier.” Eagle Hilton, Mechanical Project Coordinator, Alaskan Copper In Phase II, Alaskan Copper purchased four more 5-ton double-girder CXT cranes, and also asked Konecranes to provide and install over 700 ft. of runway for the new cranes in an existing building. The configuration of the long bay runway allowed offloading of product into smaller bays running perpendicular to the runway. RESULTS Effective sharing of responsibility with in-house teams, maintenance costs down 60% When the inspection program began, Konecranes technicians were working on the older cranes weekly. But one year later, as larger issues revealed by the inspections were resolved, Konecranes inspects just 15-18 cranes
24 25 Novelis, Oswego, N.Y. An Integrated Aluminum Facility HIGH QUALITY, COST EFFECTIVE PREVENTIVE MAINTENANCE SAVES PRODUCT INCREASES PRODUCTIVITY OVER $45K USD IN REPAIRS ANNUALLY challenge CHALLENGE Unreliable radio controls stall production No challenge yet ... Novelis, in Oswego, N.Y., is the global leader in aluminum and beverage Konecranes keeping in touch can recycling. They produce an estimated 19% of the world’s flat-rolled with a potential customer aluminum. Cranes are a critical part of the rolling, casting and fusing An integrated aluminum and manufacturing processes and are used to transport sheets of aluminum. smelting facility, located on the east coast, is one of the longest The radio control systems they used to operate their cranes began continually operating aluminum to malfunction. Without a reliable way to maneuver their cranes, the facilities in the world. Its products manufacturing process stalled, resulting in expensive downtime. serve the automotive, industrial, and SOLUTION aerospace industries. Their cranes Effective radio controls allow operators range in size from 10-50 tons and to be mobile, productive and efficient are used to handle molten metal and Out of two other proposals, the Cervis/Ikusi Hand Held and Belly Belt to transport the finished product. radio controls proposed by Konecranes stood apart as the highest quality Seven years ago, the integrated aluminum facility handled all crane products at the most cost- effective price. The controls have a heavy duty maintenance work internally. After three years of contacting the company, customized transmitter, a category level 3 safety rating, long battery life, Konecranes was able to arrange a meeting to discuss benefits of the fast chargers and position selector switches that either maintain position MAINMAN® preventive maintenance program. They liked the idea of a proactive or force return to the 0 position, which allow operators to be safe, mobile, plan for inspections, repairs and maintenance, but because they had an in- productive and efficient. house crane maintenance team, they did not have a need for it at that time. The first few radio controls that were installed worked effectively and did SOLUTION not cause downtime. Since then, over 75% of the plant’s cranes have been An occasion to inspect revealed numerous opportunities for repair switched over to Cervis/Ikusi radio controls. The next year, the integrated aluminum facility called Konecranes with RESULTS an urgent need for a complete inspection to be performed on one of Additional Smart Solutions added over time their cranes. Many of their other cranes were experiencing frequent After proving themselves with the radio control project a decade ago, breakdowns as well. The technicians completed the emergency inspection Novellis trusted Konecranes to increase their productivity in other areas. and submitted a comprehensive MAINMAN® report which included a Currently, Konecranes is developing an anti-collision system for two levels detailed assessment of the crane. The integrated aluminum facility was so of cranes – one crane on the high bay and two cranes on the lower bay. impressed with the crew and the quality of their work that they turned over The cranes will coordinate their positions use Smart Solutions technology, 15 more of their cranes for the same process. The inspections showed which helps prevent collisions. that many cranes were not up to code. Konecranes was asked to complete all of the repairs in a process that took two years to complete. The anti-collision system ensures that the crane on the high bay will not go over the cranes in the lower bay while holding a load. Smart Solutions Anti- RESULTS Sway technology is being added to three of their cranes. By preventing the load Overall savings of $45,000 per year from swinging during crane travel, the operator does not have to divide their After the extensive repair process, the cranes are in better overall attention from controlling the crane movements and monitoring the load itself. condition. Konecranes has an annual contract for inspections and planned maintenance. The amount of downtime and unplanned repairs has decreased significantly at the plant. The integrated aluminum facility now saves over $45,000 USD annually in inspection and preventive maintenance costs compared to prior years. Konecranes also performs preventive maintenance and has a site contract on all of the below-the- hook devises at other areas of the work site.
26 Westfield Industries, Manitoba, Canada MANUFACTURING CAPABILITY AND SPECIAL INSTALLATION MEETS CONSTRUCTION DEADLINE CHALLENGE New plant needed open plan and space flexibility Westfield Industries has been manufacturing grain augurs for over 50 years. Their simple, straightforward design, ease of operation and labor-saving performance have made Westfield the number one portable grain augur manufacturer in the world. This success spurred development of a new manufacturing facility near Winnipeg. Westfield’s design the roof open for a traditional, straightforward install. Konecranes was team wanted a completely open span inside the building for responsible for taking the measurements and forging a plan to install the maximum flexibility. 105’-long girders after the building was closed in. Westfield didn’t want machines permanently sited anywhere— RESULTS they wanted to be able to reposition equipment as needed Customer satisfied with “flawless” installation as augur designs evolved. For that to work, they required two Konecranes was not only responsible for installation, they also took care new cranes that could span the entire building. Manitoba-area of all of the challenges of transporting the two 105-foot cranes from lifting suppliers were unable to provide a cost-effective solution Edmonton using a special bogie wheel arrangement on a highway tractor for the cranes with the 105-foot span the design called for, as trailer rig. According to Wilcox, everything went according to plan. “We had their facilities were not set up to be able to manufacture the a great relationship, and the project worked out very well. We had a good large and long box girders required. Westfield was faced with thing going with the installation—it went flawlessly.” the possibility of having to split the shop into two 52’ sections and install a third, central runway with cranes on each side of the building. “Konecranes was much more professional than the other bidders and gave us confidence they could SOLUTION achieve our goals.” 3-ton double girder cranes with 105-ft span Brian Wilcox, Process and Quality Engineering Manager Westfield’s Process and Quality Engineering Manager Brian Wilcox contacted Konecranes for a proposal on two 3-ton CMAA class C CXT double girder cranes with a 105-foot span. Not only was Konecranes able to manufacture the cranes with exceptionally large and long girders in their Edmonton factory, they were also unfazed by a demanding construction schedule. Westfield had only a short window of opportunity to complete the building before the rainy season and could not leave
28 Limbach Company, Laurel, Md. CUSTOM INSTALLATION OF CXT CRANES AND RUNWAY SMOOTHS TRANSITION FOR CUSTOMER challenge Strict time schedule to install cranes and runway The Limbach Company was moving into a new building specifically tailored for its specialty piping business in the Washington D.C. metro area, and time was of the essence. Limbach’s capabilities include HVAC piping and plumbing, stainless steel specialty piping, design build and energy retrofit/management systems. Limbach planners needed two new cranes and a new runway, and planned to move one of their existing 5-ton cranes into the new facility. All the cranes and new runway had to be installed during several specific time windows in order to be in sync with the completion of the rest of the building. SOLUTION Successful and timely installation working around other trades Limbach’s Trade Manager Robert Davis contacted Konecranes for a proposal on two 2-ton CXT cranes, relocation of the existing 5-ton crane and engineering and installation of 240 feet of runway. “Our timeframe put them in a bit of a pickle because our construction people were installing drywall while Konecranes was building the runway,” says Davis. “However, everything went off without any problems whatsoever. Those guys did a tremendous job and were just very professional. Things went so well that I would recommend them to anyone looking for an overhead crane.” RESULTS Excellent crane performance enhances productivity A year later, Davis is still pleased with his CXT cranes, which have given him “no trouble at all.” Both of the cranes are performing exactly as promised. The impressive list of operating benefits that they deliver includes improved rope life, and fast, accurate load positioning. And, the reduced hook dimensions create more usable workspace. Compared to older hoist designs, CXT cranes can operate closer to walls and lift loads higher. For new facilities like Limbach’s, CXT improves flexibility for factory layout and material flow planning, and enables use of a smaller building shell that is less expensive to build. “we appreciate having a subcontractor that performed as well as Konecranes did. It was a positive and enjoyable experience for us.” Robert Davis, Trade Manager, Limbach Company LLC
30 APM Terminals, Elizabeth, N.J. Current and Potential Repairs identified to Keep Port Cranes Up and Running CHALLENGE analysis of each crane, repair priorities, and a suggested schedule of More complete required repairs in compliance with local statutes and laws. crane analysis needed RESULTS Nearly 4,500 containers a day Preventive maintenance saves time and reduces warranty work pass through the gates at APM Terminal’s 380-acre Port Elizabeth Because of the MAINMAN® inspections, APM has found that they rarely facility in Elizabeth, N.J. The terminal have to call Konecranes for warranty work or troubleshooting. Instead, they processes anywhere from 550,000 use the crane summary reports as a guideline for their maintenance crew to 763,000 tons of containerized to use in mapping out their workload. cargo annually. To handle the “We have 30 mechanics to look over 32 RTGs, 19 top loaders, 10 empty transfer of these massive containers handlers, payloaders, snow removal equipment, manlifts, and large from ship-to-shore and back, the facility built a fleet of 30 Rubber Tire forklifts,” APM says. “It works out to be about two machines per man, so Gantry (RTG) cranes from Konecranes. we always keep busy. We don’t have the time to do the fine-tooth comb APM facilities are required by OSHA Maritime regulations to have an OSHA- inspections that Konecranes does for us.” certified inspector examine their cranes annually. However, the basic In addition to saving time, the inspections have also caught small issues safety check performed in compliance with OSHA did not provide the Port and brought them to the maintenance manager’s attention before they Elizabeth facility with sufficient critical information about the mechanical, became major problems. structural, and electrical aspects of each RTG crane. SOLUTION Comprehensive MAINMAN® inspections “It saves us time because we With each RTG crane costing nearly $1.5 million, the Port Elizabeth do preventive maintenance facility chose to invest in Konecranes MAINMAN® inspection services to checks on the machines based on help prolong the lifespan of each crane and maximize their investment. Konecranes recommendations.” The OSHA inspection takes one technician about 1.5 hours per crane to APM Terminals complete. Konecranes MAINMAN® inspection takes three technicians working eight hours per crane to complete. That translates into a team of 15 Konecranes inspectors working on- site for up to three weeks. MAINMAN® requires a substantial amount of time because they capture data on the condition of more than 225 crane components. Konecranes certified inspectors evaluate hundreds of component parts and draw on thousands of hours of training and experience to analyze wear patterns. The results include a detailed
33Union Pacific Railroad, North Platte, Neb.PREVENTIVE MAINTENANCE AND INSPECTIONSLEAD TO TOTAL COST SAVINGSchallengeUnreliable crane performanceUnion Pacific Railroad (UPRR) helps link production and consumption pointsin the U.S., and across the world, with a network to deliver the energy, food,raw materials, durable and consumer goods to support the nation’s growth.The North Platte shop inspects, repairs and/or provides maintenanceto UPRR locomotives 24 hours per day, seven days per week. Servicesinclude: change outs of power assemblies, traction motors, alternators,turbos, engine blowers and electrical equipment. They can performthese services on 12 locomotives at one time. North Platte averages sixcomplete extensive locomotive inspections per week. Their eight criticalcranes, a variety of underhung and top running cranes ranging from 5-20ton capacities, provide lifting assistance for major locomotive componentsduring the repair and maintenance process of the cranes.Due to a lack of standardized inspection practices, timing and content ofinspections were inconsistent which resulted in unacceptable levels ofcrane reliability and safety standards.SOLUTIONInspections, preventive maintenance and modernizationsKonecranes provided and continues to provide a standardized monthlycrane inspection/preventive maintenance program to ensure the equipmentoperates in both a safe and reliable manner. Konecranes inspectors andUPRR maintenance staff work in partnership to identify safety/productivityissues and create repair plans to eliminate deficiencies in a timely manner.In addition, modernization recommendations are presented, whenapplicable, to increase the ergonomics for crane operators, speed upprocesses that require the use of the cranes and enhance the level ofsafety when the cranes are in use.RESULTSOver 60% reduction in crane repair costAs a direct result of Konecranes inspection/preventive maintenancepartnership, the North Platte shop realized a 62% reduction in emergencyrepair costs and 64% reduction in planned repair cost from 2009 to 2010.Improved crane uptime led to total maintenance cost savings.
34 A Midwest Locomotive Shop EXTEND EQUIPMENT LIFE AND ENHANCE SAFETY WITH EQUIPMENT INSPECTIONS CHALLENGE In addition to displaying the rated load, ASME B30.20 requires the Unmarked equipment fails manufacturer’s name (or contractor’s name if fabricated on-site) and lifting to meet safety requirements device weight for items over 100 pounds be displayed on structural and This Midwest locomotive shop helps mechanical below-the-hook lifting devices. link production and consumption To meet these requirements and thereby improve safety, Konecranes points in the U.S. with a network to performed an engineering study to determine the capacity of each unit and deliver energy, food, raw materials marked each accordingly. In addition, non-destructive testing was provided and consumer goods to support the to ensure material integrity. nation’s growth. RESULTS The shop inspects, repairs and provides maintenance to locomotives 24 Regulations are met, improving safety and reducing equipment overload hours per day, seven days a week. Services include: change-outs of power assemblies, traction motors, alternators, turbos, engine blowers and OSHA and ASME regulations have been met due to marking each piece of electrical equipment. On average, they complete six extensive locomotive equipment with the appropriate capacity rating, manufacturer and device inspections per week. Their eight critical cranes provide lifting assistance weight as needed. Due to the new markings and material integrity testing, for major locomotive components during the repair and maintenance overloading of the below-the-hook devices decreased, raising the level of process of the locomotives. safety within the shop. This particular shop has an abundance of below-the-hook lifting devices Of critical importance, a tailored inspection program was developed that were manufactured either in-house or are very old. These devices did to enhance safe operation of these units for everyday use and meet not meet OSHA and ASME requirements due to a lack of capacity markings. additional inspection guidelines called for in ASME B30.20. Along with Due to their age, the material integrity of each unit was also in question. creating a proactive safety environment, the inspection program may extend the life span of the equipment now that appropriate capacity loads SOLUTION are taken into account. Capacity levels determined with engineering study and NDT testing Two requirements from OSHA and ASME needed to be met, OSHA 1926.251(a)(4) and ASME B30.20. OSHA 1926.251(a)(4) stipulates that special custom design grabs, hooks, clamps or other lifting accessories, shall be marked to indicate the safe working loads and shall be proof-tested to 125% of their rated load prior to use.
37An Underground Mining Equipment ManufacturerKonecranes MTS works overtime tofinish repair weeks ahead of schedulechallengeCritical machine tool breaks downAn underground mining equipmentmanufacturer, located in the westernUnited States, is a worldwideleader in high-productivity miningequipment. Machine tools areessential components in theirproduction line.One day, a breakdown of a criticalpath machine tool, a HorizontalBoring Mill (HBM), delayed processes down the line. Every day the machinetool was down had a major impact on parts production, which created acompany-wide problem.The original equipment manufacturer (OEM) started emergency repairservices on the HBM, but was not able to complete them. The miningequipment manufacturer needed a quick turnaround in order to meet theircustomer’s demands for parts.SOLUTIONRepair completed—two weeks ahead of scheduleBecause of the comprehensive familiarity Konecranes Machine ToolService (MTS) had with this particular machine, both electrically andmechanically, Konecranes was the ideal choice for the project. KonecranesMTS was contacted and a qualified service engineer was dispatchedimmediately to evaluate, repair and rebuild the machine. The Engineerworked through weekends to satisfy the customer and the machine wasback into production in record time—two weeks ahead of schedule.RESULTSTrusted partner for the futureThe underground mining equipment manufacturer has scheduledKonecranes MTS for several modernization projects since that emergencyrepair. They continue to contact Konecranes MTS as service or preventivemaintenance needs arise.
38 39 A Mining Machinery Company A Mining Equipment Manufacturer precision calibrated machine achieves Advanced Machine Modernization highest level of accuracy Decreased Downtime and Set up time challenge While Increasing Overall Efficiency Struggling with tight tolerance CHALLENGE A mining machinery company uses Aged equipment and high maintenance costs sophisticated machine tools to A mining equipment manufacturer uses sophisticated machine tools to manufacture and repair products manufacture products for the underground mining industry. A critical for the mining industry. One of machine tool experienced downtime due to aged machine tool components. their Cincinnati Gilbert Horizontal They needed a qualified machine tool service team to modernize the Boring Mills (HBM) was struggling Giddings and Lewis Horizontal Boring Mill (G&L HBM) in order to minimize to perform tight tolerance work. downtime and reduce maintenance expenses. Because of Konecranes Machine Tool Service’s (MTS) experience SOLUTION with this equipment, they were able to use their preventive maintenance Machine redesign and rebuild program to evaluate the situation, review findings in real time, make the Konecranes Machine Tool Service (MTS) was selected to modernize the necessary adjustments and confirm the results. G&L HBM. The modernization project involved a complete redesign of the spindle carrier. The aged planetary hydraulic gear box was removed and SOLUTION replaced with a two-speed planetary gearbox system which simplified the Assessment and re-calibration headstock with fewer wear parts. The new design eliminated the need to For the Cincinnati Gilbert HBM, Konecranes MTS performed a complete replace the hydraulic valves and gears at a high price and a long lead time. assessment of the machine’s geometrical condition. Then, MTS service engineers used Mahr Federal electronic levels to precision level the A digital spindle drive system was integrated with the latest Fanuc CNC machine to exceed the original manufacturer’s specifications for pitch control system. The new CNC control system gave the facility the flexibility and roll. to control the spindle speeds between minimum and maximum available RPM when adjusting the stock removal. Konecranes developed a customized Konecranes MTS state of the art Renishaw ML10 interferometer laser control pendant equipped with an LCD screen which enhanced safety by system was used to calibrate the positioning accuracy of the machine. allowing the operator to have closer access to the parts they set up. After the machine had been precision leveled and laser calibrated and a Renishaw ballbar had been run to confirm the results, the mining machinery RESULTS company was able to confirm with their coordinate measuring machine Reduced cost and downtime, increased throughput substantial improvements in their product’s quality. The Giddings and Lewis HBM modernization decreased downtime while increasing throughput and efficiency. Maintenance costs were greatly RESULTS reduced. Konecranes will continue to perform preventive maintenance, Highest ever level of accuracy, beyond original specifications calibration and service support. After Konecranes MTS optimized the Cincinnati Gilbert HBM, it performed at the highest level of accuracy ever achieved in its lifetime. The improved machine repeatability and accuracy reduced set up time for parts by minimizing the necessary adjustments to accommodate the machine’s geometry issues.
40 A Leading Mining Manufacturer OPERATOR TRAINING IMPROVES SAFETY, PREVENTS EQUIPMENT DAMAGE AT a GYPSUM QUARRy challenge RESULTS Frequent breakdowns from Operator training + new cranes = long term relationship suspected improper use The success of the operator training program in reducing equipment A leading manufacturer of gypsum damage led to Konecranes having contracts for virtually all of the wallboard operates a quarry in North customer’s crane maintenance needs. The mine also began purchasing America. The quarry processes up new-generation Konecranes CXT cranes with variable speed bridge and to 20,000 tons of rock per day, trolley motions and built-in load limiting devices to replace older cranes. which is extremely hard on material The numerous safety and low-maintenance features of the CXT were an handling equipment. excellent fit for the mine, where reducing maintenance expenses is a prime objective. The mine uses a fleet of 10-ton overhead cranes to maintain large According to the mine’s maintenance planner, the training program has transfer trucks and other mining made all the difference. Now, every crane operator must complete the equipment. They had frequent crane operator safety course in order to operate a crane at the facility. crane breakdowns and experienced Konecranes has become a valued contributor toward improving the mine’s problems with ropes being pulled off the drums when the loads were too safety and production. heavy for the cranes, allegedly from improper operator use. Only a few of their cranes had load limiters installed. Purchasing higher-capacity equipment was not an economical option. SOLUTION RFQ for maintenance led to operator training as the fix The mine began looking at outsourcing crane inspections and maintenance. An analysis of contractors based on a formula comparing rates, documentation, competency of technicians and other factors revealed Konecranes as the leading supplier. The relationship began with Konecranes providing inspections only, with the mine performing repairs and maintenance on the items Konecranes identified. After seeing the recurring damage caused by operators attempting to lift loads too heavy for the equipment, Konecranes recommended that they implement a mandatory crane operator safety training program. Going back to the equipment manuals, Konecranes showed operators how to break down the trucks into elements weighing 10 tons or less sections that the , equipment could handle. The safety training program showed the operators the basic methods of calculating the weight of identified sections.
43Elevating Boats, LLC, Braithwaite, La.Advanced machine restoration enhancessafety and improves ease of usechallenge BeforeCritical machine damagedby Hurricane KatrinaElevating Boats (EBI), LLC in Braithwaite,La. uses machine tools to manufactureoffshore lift boats, pedestal cranes,hydraulic cylinders and many othermechanical and hydraulic componentsfor the global boating industry. Machinetools are essential in manufacturing their Afterproducts and components.In 2005, a highly-specialized vertical boringmill (VBM) was damaged in HurricaneKatrina. As a core machine to the EBIproduct line, the loss of this machinereduced their capacity to meet the demandsof their customers.Three proposals were generated for this project. Konecranes MTS waschosen based on having the best value proposition because Konecranesemployed the most talented technological team, with experts in everyarea required for the project. The plant manager at EBI had worked withother retrofitters in the past, but he did not believe that they had enoughmechanical expertise to retrofit this machine.SOLUTIONKonecranes MTS retrofits machine, adding safety featuresKonecranes MTS performed a complete retrofit of the machine. Anadvanced feature was added which allowed for a more dependable locationof the movable rail through a process called synchronous axis control. Thisimprovement enhanced safety and made the machine easier to operate. Anadditional enclosure was added for safety.RESULTSThe machine is completely restored, with added featuresThe machine was restored to its original geometry and positioningspecifications. The updates allowed the operator more flexibility forassembling complex parts. Because of the project success, KonecranesMTS is the favored supplier to rebuild and retrofit another machine.
44 National Oilwell Varco, Houston, Texas Enhancing safety with crane operator training course challenge The instructors put their knowledge in layman’s terms and performed Crane operators hands-on training to show employees proper rigging techniques, load need training support ratings, and inspections on their own equipment. When industry leader National “Of all the training programs I reviewed, the Konecranes Institute Oilwell Varco (NOV) in Houston, presented the best course outline, offering the most comprehensive Texas, began searching for a strong coverage within a good time frame,” says Christy Exley, Health, Safety, crane operator training program Environment (HSE) Manager at NOV in Houston. “The Konecranes Institute that could enhance safety and offers a true Train-the-Trainer class,” says Exley. “One of its greatest increase awareness at multiple benefits is that the instructor teaches not only overhead crane operation, NOV facilities, the company but the basics of becoming an effective instructor.” singled out the Overhead Crane Train-the-Trainer course from the RESULTS Konecranes Training Institute. The Training considered number one accomplishment of the year program provides a cost-effective Vernon Miller, corporate HSE regional manager for NOV, says that NOV approach to training personnel, employees received the knowledge to move forward safely. “Looking back presenting future trainers with on the accomplishments my group has made this past year, the Institute basic to complex information, and training is the number-one selected achievement that was accomplished,” equipping them with instructional says Miller. skills to train employees internally throughout the company. Instructors of the Konecranes Training Institute have extensive “Even employees with more than 15 years overhead lifting experience, teaching first-hand knowledge about experience said they came away from the proper crane operation, maintenance, and best practices to improve course having learned something new.” safety and compliance, productivity, and lifecycle value of equipment. Christy Exley, Health, Safety, The Institute has trained operators in industries such as steel, Environment (HSE) Manager, National Oilwell Varco utilities, chemical, automotive, foundry, nuclear power, mining, aerospace, paper and waste-to-energy. SOLUTION Konecranes provides comprehensive, hands-on training In the fall of 2008, several NOV facilities throughout the country received on-site Train-the-Trainer instruction from the Konecranes Institute. NOV crane operators with varying levels of experience, from as few as two years to as many as 25, participated in the training program.
46 A Southern Manufacturing Company equipment breakdowns Decreased by 60% with proper maintenance CHALLENGE Four to six breakdowns per week A Southern manufacturing company develops specialized equipment for the oil and gas industry. Each of their 16 25-ton overhead cranes is essential to meeting the high production needs of the facility. The company that had been servicing their cranes tended to focus on problems after they occurred, rather than working to prevent them. As a result, the cranes had an average of four to six breakdowns per week. When the Southern manufacturing company noticed that their cranes were experiencing the same type of breakdown repeatedly, they began to look for a new company to service and maintain their equipment. SOLUTION MAINMAN®inspections and preventive maintenance The Southern manufacturing company contacted Konecranes after one of their critical cranes experienced a breakdown during off-peak hours over a weekend. A Konecranes emergency response team was dispatched immediately upon being contacted. After successfully completing the repair, Konecranes proposed an annual inspection contract for each of their cranes using the MAINMAN® inspection program. MAINMAN®is an active preventive maintenance program that uses a multi-point visual inspection to capture data on the condition of over 225 crane components. The data is then used to create a customized plan for scheduled maintenance and repairs. Konecranes currently conducts annual MAINMAN® inspections at the facility and completes scheduled preventive maintenance repairs as needed. RESULTS Breakdowns decreased by 60%, overall decreased costs Since Konecranes began conducting preventive and planned maintenance two years ago, equipment breakdowns at the facility have decreased by over 60%. As a direct result of the MAINMAN® inspection program, maintenance spending and downtime expenses have been dramatically reduced.
48 BC Hydro, Mica Generating Station, British Columbia TECHNOLOGY DEVELOPED FOR NUCLEAR INDUSTRY EXPEDITES UNDERGROUND CRANE INSTALLATION challenge the cavern without removing ceiling Specialized installation needed supports or, most importantly, for underground facility disrupting power generation. When BC Hydro built their Mica generating station This patent-pending jacking tower, on the Columbia River in 1977, it was designed the only one of its kind in the world, to hold six generating units. But only four were was delivered by tractor-trailers initially completed, pending a need for more power and assembled inside the cavern in the region. to the required height. The jacking In 2011, the Mica Units 5 and 6 Project was tower rests on a base that allows launched to install the two remaining generating for even load distribution, one large units, adding another 1,000 MW of power advantage over mobile cranes, whose tires have a very small footprint. generating capacity. Another advantage is a jib arm that can be used to raise and lower To service them, BC Hydro bought two new turbine smaller loads. The jacking tower not only has the ability to remove all hall cranes from Konecranes, designed to work in components from under the crane rather than above, but it also installs tandem to provide synchronized lifts. At 575 tons the cranes from below. each, these massive double girder cranes were RESULTS the largest ever delivered by Konecranes in North Equipment installed with minimal production interruption America to date. According to Owen Williams, BC Hydro’s project manager, Konecranes Because the entire Mica facility is carved into jacking tower technology and its ability to install from below was a real a mountain, the cranes must operate inside an advantage in the underground location. underground chamber accessed by a 400-foot “Konecranes had an elegant way of replacing the existing cranes with new tunnel. Normal installation inside the underground ones which allowed us to install new cranes while having a limited impact facility using mobile cranes was not an option, as on the operating generating station,” he said. they would not fit in the limited headroom without removing ceiling supports. “Our generating station continued to provide SOLUTION approximately 15% of BC Hydro’s total power One-of-a-kind jacking tower generation output during this project.” installs equipment from below Working with Konecranes Nuclear Equipment & Owen Williams, Project Manager, BC Hydro Services, Konecranes utilized a state-of- the-art technology developed in 2010 for the nuclear industry to make the challenging install inside
50 R.E. Ginna Nuclear Power Plant, Ontario, N.Y. Specialized Crane Enhances Safety Through Advanced Engineering challenge This was accomplished by designing a High-capacity crane needed hybrid single failure proof crane that was to handle spent fuel actually installed outside of the crane When R.E. Ginna Nuclear Power operating area, but that is able to access Plant needed a specialized high the crane operating area by telescoping capacity crane to be able to off-load into the building. This is no small feat spent fuel from their fuel pool to considering the crane is rated at 125- dry cask storage, they trusted the tons, is single failure proof and that it expertise of Konecranes. reaches into the building to pick up spent nuclear fuel. “We needed to find a partner that could provide us with a significant RESULTS capacity crane and crane configuration dedicated design. One of the Konecranes continues to provide challenges was the fleet cask size – a 125-ton cask – that dictated crane service and support crane configuration,” says Mark Fitzsimmons, Principal Engineer, Nuclear “The crane was installed and delivered on Engineering Services, from Constellation Energy Nuclear Group. time, but there were some original materials that weren’t as compatible as we would SOLUTION have liked. But Konecranes supported us Crane developed to meet space, capacity, through the problems, and we ran our first safety and regulatory requirements campaign without a hitch.” After a competitive bid process, Konecranes was selected as a turnkey supplier of a complex single failure proof crane. Konecranes is now under contract to provide maintenance service for the crane, During the process of assessing the project, a new challenge was thereby ensuring that it is properly cared for determined: the building structure surrounding the fuel pool was not originally during its lifetime and that it will perform designed to support the weight of a fully loaded 125-ton single failure proof the key tasks that are necessary to load crane that was required to move and load the spent fuel for dry cask storage. and handle spent nuclear fuel. Konecranes and Ginna worked closely together during the entire project to make sure the solution would meet the demanding requirements. According to Mark, business is growing and they will need high performing cranes as well as support for older cranes on a fleet-wide scale. This could Handling spent nuclear fuel is a highly specialized task and requires lead to opportunities for more successful joint projects in the future. compliance with strict and comprehensive regulatory requirements of the U.S. Nuclear Regulatory Commission. Konecranes knew that it had the technical knowledge to solve the problem, along with the ability to comply “Konecranes came up with a new solution based on our with the stringent requirements of NUREG-0554 and ASME NOG-1 single current situation. It was an innovated idea, and they failure proof crane design criteria. presented a model that showed the outcome.” Mark Fitzsimmons, Nuclear Engineering Services, Principal Engineer
54 Liberty Paper, Inc., Becker, Minn. Crane Modernization goes over and above to win long-term relationship challenge Determine the current condition and remaining life of a dry end crane Liberty Paper, Inc. (LPI), part of the Liberty Diversified International family, is a state-of-the-art paper mill, located in Becker, Minn. that recycles old corrugated containers into new paper for packaging. The mill manufacturers recycled paper from more than 240,000 tons of corrugated containers each year. In June 2009, the company turned to Konecranes to complete an end-of-life study on their dry end crane, used primarily in the manufacturing process. The crane had originally been purchased from Konecranes in 1994. SOLUTION Konecranes end-of-life study used to scope a modernization A Konecranes sales representative explains, “This gives them a lot of After the end-of-life study was complete, LPI received three quotes to flexibility in the future.” upgrade the equipment. Konecranes provided the best added value Sixty cycles after the modernization was completed, the hoists were tested proposition to LPI, therefore, Konecranes was awarded the job in April for synchronization, which is crucial in the paper process. These critical 2010. The primary factor was because of the end-of-life study. Konecranes hoists ran in tandem within one inch of each other offered an immediate solution that allowed for future expansion plans. Since the installation, Liberty Papers has signed a service contract with In August 2010, Konecranes installed the modernization to the dry end Konecranes. The service contact includes monthly preventive maintenance. crane. Konecranes worked around the clock, beginning Monday at 6 a.m. The job was completed by Friday at noon – 24 hours ahead of the deadline. Currently, Konecranes and Liberty Paper are discussing plans to perform The installation came in on budget and required no downtime from LPI. these same modernizations to an LPI wet-end crane. RESULTS Modernization completed on time and on budget, cranes equipped with excess capacity for future expansion Both hoists were modernized to 30-ton. The hoists were then de-rated to 20-ton cranes, allowing them ample expansion room for future plans.