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Konecranes investigates the hoisting gears of the critical overhead cranes at the Palm paper factory, with Oil Analysis and Crane Reliability Study (CRS)

Churning out corrugated base paper: The paper machine 6 (PM6) at the Palm paper factory in Wörth am Rhein, Germany, annually produces some 650,000 tons of the versatile packaging raw material with surface weights of up to 160 g/m2. In order to safely transport these huge paper rolls day and night, the double-girder bridge cranes inside the factory must always function flawlessly. For this reason, Konecranes has closely analyzed the gear oil of the cranes and used the endoscope to look deep inside the gears.

Paper remains one of the most important resources for the economy: According to the association of German paper factories, the paper industry sold approximately 23 million tons of paper, cardboard and paperboard in 2017 – up 1.4 percent from 2016. The packaging industry is especially hungry for paper. Sales in this sector increased by 3.4 percent last year alone. This is the area of operation for the paper machine 6 (PM6) at the Palm paper factory in Wörth am Rhein. The 650,000 tons of corrugated base paper it produces each year is handled at various stages by eleven double girder overhead cranes, all playing their own crucial role in the paper production on PM6. In order to safely transport these large paper rolls day and night, the hoisting gears of the eleven cranes inside the factory must always be in top operating condition. For this reason, Palm has asked Konecranes to look at eight of its most critical cranes.

A deep look inside the crane gear: With the Konecranes oil analysis, wear traces, such as rust or metal particles in the gear oil, can be identified and unplanned downtime can be prevented.A deep look inside the crane gear: With the Konecranes oil analysis, wear traces, such as rust or metal particles in the gear oil, can be identified and unplanned downtime can be prevented.

Following the results of the oil analysis and subsequent endoscopic investigation, the maintenance experts identified a significant risk to future production and replaced one of the hoisting gears completely.

Record paper machine produces around the clock

At the Palm paper factory, located in Aalen in Baden-Württemberg, everything circles around recovered paper. Nine paper machines in five factories annually produce approximately 2.2 million tons of newsprint and corrugated base paper. The paper production continues around the clock. Correspondingly high are the demands from the eleven double-girder bridge cranes that have been in use in the factory in Wörth am Rhein since the start of production in 2002. Collectively, they handle and store the completed paper rolls that weigh many tons. “The cranes are in use day and night,” says Sven Bohrer, electrical engineer at the Palm paper factory. “If one should break one day, the production would have to stop, or at least greatly slow down, until the problem is solved. This would cost us time and money.” For this reason, Konecranes has closely investigated the gear oil of the hoisting gears of eight of the eleven double-girder bridge cranes at Palm. Because you can look deep inside the oil, the wear metals and waste substances it contains make it possible to draw conclusions about the state of the entire gear. Nico Zamzow, Vice President Industrial Service EMEA Central at Konecranes, comments on the method: “The oil analysis protects the crane. Any damage can be identified and treated early with its help. Moreover, system operators are able to optimize the maintenance and servicing of the cranes thanks to the detailed analysis report, and thus significantly increase their lifespan.”

For the oil analysis at Palm, Konecranes experts took samples from the hoisting gears of the eight double-girder bridge cranes. “The samples are analyzed by our laboratory, which specializes in industrial drive train analysis. Here, the lab staff compares the current state of the oil with the samples taken in 2016 and against the OEM design limits,” says Nico Zamzow. “This way, we also use trend analysis to provide the best possible picture of any change within the condition of the gearbox.” The result for Palm: Seven of the eight cranes were found to be “healthy”, as in the gear oil contained few to no foreign elements or waste substances indicating contamination or wear. However, the gear oil of the automated number 5 crane, used in the roll warehouse, was found to have a noticeable increase in its wear partial count, triggering the lab to issue a “Caution” notification on the analysis report. Nico Zamzow: “Iron particles in the oil can be an indication of increased wear and a deeper look may be required for this particular hoist”.

A closer look: The cranes in the roll warehouse of the Palm paper factory are in use at all times. For this reason, one important element of the Konecranes CRS is inspecting the crane systems for signs of wear.A closer look: The cranes in the roll warehouse of the Palm paper factory are in use at all times. For this reason, one important element of the Konecranes CRS is inspecting the crane systems for signs of wear.

Crane Reliability Study has the solution

If the reason for the wear is not clearly identified and removed, the gear may be permanently damaged. “If the gear is jammed while there is a roll on the hook, it becomes very difficult to recover it and repair the crane,” explains Nico Zamzow. In order to determine whether there is already damage, the Konecranes experts used the Crane Reliability Study (CRS). The modular analysis allows them to check safety-relevant components, such as the hoisting gear as well as the steel structure, the motors, and the electrical equipment of the crane. In addition, the maintenance experts pose questions to crane drivers and technicians. The analysis result flows into a detailed report for crane owners – with concrete recommendations for action. In the case of Palm, Konecranes used a high-definition video endoscope to investigate the hoisting gear. “Just like in medicine, we use the endoscope to reach inaccessible places without having to dismantle the entire gear,” says Nico Zamzow. “For the CRS, we use a special, oil-resistant model that was developed for industrial use and can be fitted with different lenses.”

Following the endoscopic investigation, the Konecranes service experts are certain: The hoisting gear must be replaced. In addition, the cable drum, the cable drum support, the slip-ring unit, the cylinder coupling, and the motor coupling must be renewed. “Thanks to discovering the wear early on, there was no risk to safety and we were able to replace the old gear with a new one without affecting production,” explains Nico Zamzow.

“The benefits of Oil analysis as a predictive maintenance tool for identifying problems early on is proven to minimize the risk to production and safety. We, in the United Kingdom, now offer this as a standard solution to support our existing customers,” says Mark Goringe, Konecranes Industrial Service - Area Director, Mid West Europe.

Task distribution: Konecranes experts analyze the gear oil of eight of the eleven double-girder bridge cranes that are used in the large paper machinery hall and in the fully automated roll warehouse.Task distribution: Konecranes experts analyze the gear oil of eight of the eleven double-girder bridge cranes that are used in the large paper machinery hall and in the fully automated roll warehouse.

Transport will remain safe

The Palm paper factory will continue to use services such as maintenance and servicing from Konecranes. Jürgen Friedmann, head of Mechanics at the Palm paper factory, is happy with what has been achieved: “Konecranes experts have had a very flexible approach to our demands for the availability and productivity of our cranes. Thanks to the oil analysis and the endoscopic investigation, our cranes will now run without issues in the years to come.”
Konecranes is one of the world’s leading brands in Lifting Businesses™ and supplies production enterprises and process manufacturing, shipyards and harbors with innovative lifting technology solutions. Besides productivity-increasing lifting solutions, Konecranes also offers customized services across the whole spectrum of lifting machinery. Konecranes has 16,200 employees at 600 locations in 50 countries. Konecranes stocks are quoted on the Helsinki stock exchange (Nasdaq Helsinki Ltd) under the abbreviation KCR1V.

Konecranes is one of the world’s leading brands in Lifting Businesses™ and supplies production enterprises and process manufacturing, shipyards and harbors with innovative lifting technology solutions. Besides productivity-increasing lifting solutions, Konecranes also offers customized services across the whole spectrum of lifting machinery. Konecranes has 16,200 employees at 600 locations in 50 countries. Konecranes stocks are quoted on the Helsinki stock exchange (Nasdaq Helsinki Ltd) under the abbreviation KCR1V.

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The paper manufacturing is characterized by a long and complicated process. From the transformation of wood into pulp, over the winding paper web into rolls, and subsequently the rewinding and cutting of these giant rolls into smaller ones, through the automatic storage for converting, sheet cutting, or customer delivery. The paper mill works fast, and the products need to be shipped on time to meet demanding customer schedules. Unexpected downtime can’t be afforded.

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Konecranes develops paper mill cranes to help boost long-term reliability and minimize ownership costs. © Konecranes

Konecranes understands the processes of the pulp and paper – from wood handling to recycling -  and has been meeting the needs of this industry for decades by providing cranes and other lifting solutions that help to increase productivity, maximize efficiency, as well as avoid downtime and costly problems right from the start.

Selecting from an unmatched portfolio of superior products, Konecranes can deliver integrated solutions – starting with the unloading of raw materials and continuing every step of the way to the shipping of the finished paper products. The company has end-to-end expertise covering planning, engineering, delivering, commissioning, and servicing lifting solutions for all pulp and paper operations. The know-how offered by Konecranes can start with a feasibility study and extend to cover the complete maintenance of lifting equipment and tools throughout their lifecycle.

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Konecranes offers specialized service for the pulp and paper industry that helps to improve safety and decrease the cost of downtime. © Konecranes

Paper mill cranes and material handling system

Konecranes has designed paper mill cranes to help boost long-term reliability and minimize ownership costs for pulp and paper industry. The solutions are based on long experience and know-how of the industry environment, and the process. This know-how is based on Konecranes’ own resources and close collaboration with machine suppliers and engineers. Konecranes provides cranes and material handling systems for all lifting applications in the pulp and paper industry, such as process duty cranes, maintenance cranes, parent roll handling cranes, paper roll storage systems, workshop cranes, as well as maintenance services. Cranes used in the pulp and paper industry are used as an integrated part of the production process and maintenance.

 Moreover, the applications provided vary and cover the fields of wood handling, pulp production lines, paper and paperboard production, deinking plants, tissue paper mills and converting plants, intermediate storage, and shipping.

Paper Roll Storage Solutions

Konecranes’ warehouse management system (WMS) and the automatic paper roll handling crane design for unpacked and wrapped storage rolls help to save space and time. The automated vacuum lifter economizes the warehouse capacity of the available space. Furthermore, software for the storage administration system and crane automation with purpose-built machineries form an integrated handling system. Mechanical roll grippers can handle wrapped rolls and multiple rolls at a time for higher input/ output of smaller roll sizes.

In addition, Autostore helps paper mills operate more efficiently by eliminating capital and labor costs. Storage automation keeps the inventory fresh, clean, and current and provides up-to-date information.

Excellent, proactive service

Konecranes provides an extensive range of services for the pulp and paper industry that can cover a single item or all lifting equipment. The offered specialized service helps to improve safety, decrease the cost of downtime, and increase the productivity of uptime. With a global network of maintenance professionals working from more than 600 service depots around the world, Konecranes can service any make of crane and hoist. Services include inspections, repairs, maintenance, and modernizations of cranes and other lifting equipment worldwide.

In addition, Konecranes offers the unique TRUCONNECT® Remote Monitoring and Reporting service, which provides actual crane usage data. TRUCONNECT® periodic data reporting and real-time diagnostics allow customers to optimize crane maintenance activities and give visibility to crane maintenance and application compliance.

Konecranes is a world-leading group of Lifting Businesses™, serving a broad range of customers, including manufacturing and process industries, shipyards, ports and terminals. Konecranes provides productivity-enhancing lifting solutions as well as services for lifting equipment and machine tools of all makes. In 2013, Group sales totaled EUR 2,100 million. The Group has 11,800 employees at 600 locations in 48 countries. Konecranes is listed on the NASDAQ OMX Helsinki (symbol: KCR1V).

www.konecranes.com

Further information:

Konecranes

Lena Ansorge, Marketing & Communications

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Phone +49 6103 7333-235 | Mobile +49 162 2824233

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Remote services are one of the newest innovations in Konecranes service business. Based on a remote connection we are able to help our customers to improve the safe use of their equipment, provide the right maintenance at the right time and asses the lifecycle of crane components.

 

The TRUVIEW remote data monitoring and reporting service provides the customer with a true view of their crane’s operating condition through continuous data collection. For the customer this means improved safety and higher efficiency as crane maintenance can be planned according to the crane’s actual usage and condition. TRUVIEW collects usage data from the crane through a remote connection and compiles that information into a customer report that is available for the customer at their dedicated online customer portal. The portal offers easy access to the history data of the crane with important crane specific key figures in real time.

 

Through the power of information, TRUVIEW offers three distinct benefits for the customer. One, it helps the customer to increase safety as overloads, emergency stops and other safety issues are captured and clearly brought to customer’s attention. Second, it enables the right maintenance at the right time based on real crane usage and condition. Third, the customer is able to see how the hoist is actually used and thus can plan and budget maintenance actions in advance.

 

TRUCARE is a 5-year full service contract built around the TRUVIEW service. With a fixed cost, the customer gets the full service portfolio including maintenance and inspections, wearing parts, troubleshooting, spare parts and repairs. With TRUCARE the customer doesn’t suffer from surprising extra costs and can focus on its core business since the cranes are taken care of by Konecranes.

 

These two new service products belong to the TRUCONNECT remote services product family which was introduced at the beginning of May. Currently TRUVIEW and TRUCARE services are available for industrial cranes, but TRUVIEW solutions for other equipment will follow soon.

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get_imgThe new Konecranes Boxrunner straddle carrier offers unique container handling performance to two distinct container handling operations. The first is represented by large container terminal operators that are adopting automation technology for greater efficiency. The second is represented by a potentially diverse range of companies that do not have container handling as a core competence, and yet handle incoming and outgoing materials in containers – often using trucks and trailers or custom-engineered, stationary gantry cranes. Boxrunner can be a much more effective solution for their container handling needs.


Boxrunner is the product of Konecranes’ long experience in the straddle carrier business and a deep understanding of the needs of container handling operations. The design process started by asking a number of key customers the question: “What are the characteristics of the perfect straddle carrier?” Their answers inspired the Boxrunner’s principle performance and ownership characteristics i.e. speed, outstanding handling, durability, operator friendliness , low maintenance with long service intervals, and a low total cost of ownership.


“We listened to our container handling customers and incorporated their feedback resulting in the launch of this special machine, the Boxrunner, a uniquely advanced straddle carrier,” says Jens Andreas, General Manager, Konecranes Straddle Carriers. “It provides the industry’s highest lifecycle value in the role it was designed for.”


The Boxrunner is a machine for professionals who care about long-term benefits based on lifecycle cost calculations that take into account performance metrics, fuel efficiency and maintenance interval length.


Quayside flexibility

The Boxrunner gives large container terminal operators a flexible and efficient means of moving containers from ship-to-shore (STS) cranes to the automated stacking cranes (ASCs). The key word here is flexibility. Boxrunner can deal with almost any requirement during this phase of the operation e.g. boosting STS unloading speed to maximum or handling containers of different ISO sizes. The Boxrunner is adapted to handle all ISO container sizes, stacking two-high at high speed.


“We have a very simple formula for delivering customer value,” says Andreas. “We maximize the productivity of uptime and minimize the cost of downtime with the Boxrunner, thus boosting the productivity of our customers’ operations.”


Konecranes designs and manufactures Boxrunner’s key components in-house to make sure they work together flawlessly. The new straddle carrier is built around a very rigid structure that provides excellent handling performance and direct steering. Powered by a diesel-electric (DE) drive and rope hoist system, the Boxrunner is offered as a 50 t twin twenty lift machine and as a 40 t single lift machine that can travel at 30 km/h with a 25 m/min hoist speed. “Boxrunner is a technologically advanced machine that is truly driver-friendly and maintenance-friendly,” says Jost Dämmgen, Sales Manager, Port Cranes. “We want to deliver high-performance, high-quality vehicles to our customers. The Boxrunner exceeds expectations for drive feel and performance, and meets expectations for reliability, safety and maintenance.”


Unique Konecranes technology

The Boxrunner uses Konecranes’ unique rope and drum hoisting system, a proven technology from the company’s popular rubber tired gantry cranes (RTGs) and rail mounted gantry cranes (RMGs). It also has an electronic-hydraulic system with four-cylinder steering for less tire wear, fewer spare parts, a greaseless gantry and very low maintenance. The driver’s cabin is a model of ergonomic design providing excellent visibility. Its simple controls and displays help to ensure safety, accuracy and speed.


“With space in short supply at ports and quays, the Boxrunner is an excellent choice because it can take on several roles, eliminating the need for other container transport equipment. It is very stable and has excellent straight driving characteristics thanks to its 4-axle steering system. Comparatively speaking, every operator that has tested the Boxrunner has been impressed by its superior drive feel and sense of control aided by innovative and intelligent displays.  Moreover, we offer our customers outstanding service packages,” says Andreas.


As a major global player in the design, manufacture, delivery and servicing of container handling equipment, Konecranes is pleased to offer its new Boxrunner straddle carrier to demanding customers worldwide and expects to make the first delivery during Q1/2011.

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