Unchanged crane runway thanks to load-dependent positioning The challenge at the Jochenstein power station was to increase the load capacity to 120,000kg per crane while maintaining the same wheel loads. In addition, the approach dimensions specified for the old crane system had to be maintained. Furthermore, the span of the crane runway changes when switching from the straight runway section to the curved section. For this reason, the end carriage, which connects the crane girder to the running gear, has a design with special wheels. In the centre of the crane bridge, the trolley has a travel range of 5,470mm. This range was defined to allow the rotor to be lifted out. The rope drum with a diameter of 800mm is now made of sheet metal instead of the standard 610mm round tube. Lifting beams are used to distribute the load evenly. The wheel loads remain unchanged as the maximum load is limited to the centre of the crane bridge. A special operating mode was set up for this purpose, which allows travel with 120,000kg only in this centre range via a safety circuit. This meant that the old crane runway could be used without any complex modifications, even though the crane can now transport significantly higher loads. Instead of conventional travel limit switches, safety encoders detect the positions of the hoists. These were also used to implement a position-dependent overload detection system, enabling a performance level rating of D to be achieved. Now, rotors weighing 220t can be lifted out without dismantling the poles. This saves considerable time and reduces the costs of inspecting and maintaining the five generating
Specially constructed 800mm rope drum made of sheet metal instead of standard round tube.
sets. After being lifted out, the rotor is transported to the opposite side of the Danube, where it is stored for the duration of the inspection. The total crane runway length from the powerhouse to the Austrian bank is around 250m. Its occasional outdoor operation required the system to be specified for an ambient temperature range of -10°C to 40°C.
Double load in tandem operation In tandem operation, double the load can be lifted, for example, 240t – this is sufficient for the rotors, including their poles. Tandem operation enables efficient handling of the rotors and their safe transportation out of the powerhouse and over the weir. In the past, tandem operation required two experienced crane operators who had to work closely together to navigate the heavy, bulky loads safely and precisely. Today, radio control systems are increasingly being used for tandem lifts to coordinate the movements of the cranes and trolleys, with various operating modes available. The radio remote control is integrated into the crane’s data bus. Both
cranes communicate with each other via an industrial WLAN to enable tandem operation. The cranes have an auxiliary hoist unit with a lifting capacity of 16,000kg, which is used in addition to the main hoist unit and is controlled together with it in tandem trolley mode. The main purpose of the auxiliary hoist is to move loads precisely during delicate lifting operations or assembly work in double-load operation. It enables flexible working, saves time and increases the efficiency of the entire crane system. It is also approved for transporting people as a recovery winch. The auxiliary hoist has two load measurement systems: one for regular loads and one for operating the workman basket. Depending on the operating mode, the signals are processed in the control system.
Mechanics and programming – a special solution The hoist has load and speed sensors, limit switches and actuators, all of which (apart from the speed sensor) are integrated into the crane’s data bus. Instead of a hard-wired control unit, a programmable KSK-S complete controller is used. This system is modular and expandable, providing options for partial automation. Monitoring when moving the crane or load handling equipment is improved – error messages and operating statuses are output via a specially programmed user interface (Human Machine Interface) and shown on the display. The new crane system at the Jochenstein
The generators in the powerhouse have a diameter of over 7m.
hydroelectric power station has been in operation since the autumn of 2024. The new crane is now used for transporting many heavy loads at the Jochenstein hydropower plant. Mechanically and in terms of programming, this is a special solution that was tailor-made for Verbund. A particular advantage of the STAHL CraneKit is its flexibility, which allows it to be easily adapted to the specific requirements of the respective application. The entire rotor was successfully lifted out for the first time at the end of November 2024. Because of the excellent results, further projects with Verbund are in planning.
www.hoistmagazine.com | June 2025 | 9
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