There is also a 35 tonne KONECRANES LV open winch crane with 30 metres span is also ordered for the casthouse which will be used with two lifting beams for liftin the hot metal crucibles. This crane will have air conditioned cubicles and invertor drives.

Also for the October delivery contract are a 15 tonne and two 12 tonne potline services cranes with 24 metre spans. The 15 tonne model will operate with two 2 x 7.5 tonne SM trolleys and one of the 12 tonne cranes will have a 6 tonne auxialiary hoist fitted. The last crane in this contract is a 3 tonne CXTD single girder crane for use in the GIS building for handling the switching and transformers which will have 2 speeds on all motions. All the cranes will have Konecranes state of the art controls and monitoring facilities.

Click on picture to view/download a hi-res edition
BAE construction hall	Astute Class Submarine	From the left: Jim Strathie Konecranes UK; Ian Gowans, BAE Systems; Graham Kirkwood, Konecranes UK and Phil Foley, BAE Systems

BAE Systems are contracted to build Astute Class Submarines for Britain’s Royal Navy at their yard at Barrow-in-Furness in Cumbria. BAE Systems employ over 3,000 staff at their Barrow yard, many of whom work in the main construction hall. The hall measures an incredible 60 metres wide and 50 metres high. All major crane manufacturers in the UK were considered for this £7.5million contract. These were then narrowed down to three with KONECRANES UK scoring highly on all criteria. Of particular note was their design experience relating to this type of crane and also the fact that KONECRANES UK enjoy the reputation of previously being the UK’s most experienced constructors of large single girder cranes and BAE were highly impressed with KONECRANES UK’S corporate approach and the depth and strength of their organisation.

In order to meet the stringent safety requirements for nuclear related facilities a periodic review was undertaken by BAE Systems to ensure that the existing construction of the cranes would meet modern nuclear safety requirements. The safety review showed a shortfall against the new requirements and the cranes needed strengthening. The original cranes were supplied by J.H.Carruthers, now part of KONECRANES UK, in 1984 whose original designer, coincidentally, still works for KONECRANES UK. Now young designers are following in his footsteps, and at least one of the original fabricators is also still involved. In addition, KONECRANES UK’s Managing Director, Gordon Adie, was in charge of the original contract on the old Vickers Shipbuilding and Engineering site when they were building Trafalgar Class Submarines. Currently our biggest single contract in the UK, KONECRANES UK has placed a dedicated team on this.

KONECRANES UK is one of the few companies that can support this kind of contract with the Enhanced security features that need to be used. The contract is to provide five modernized enhanced security cranes, cranes that will not collapse when carrying a sensitive load or during certain seismic events. These comprise two 150 tonne (2 x 75t) cranes (which can be used in tandem to lift a 300 tonne load) and three 12.5 tonne cranes. The larger cranes are referred to as “A Type” cranes and the smaller as “B Type” cranes. This is purely a means of categorisation and not a reflection on performance or quality. Enhanced security features include strengthening to withstand a seismic event and also decreasing capacity of the Type B cranes from 30t cranes to 12.5t cranes to increase safety margins. The cranes employ a “positive capture” system and minimized drop stops designed to prevent the derailing of the crane gantry or the trolleys under seismic fault conditions. The type A cranes run on multiple wheels for better weight distribution and these are drop forged steel instead of cast SG iron to prevent fracturing at low temperature. The gearboxes are also now all fabricated steel rather than made of cast material. The original main hoist rope drums on the type A cranes were for multi-layering of the ropes, however the new drums will be single layered to protect the ropes and provide better speed control in tandem lifting. PLC Control systems incorporate hard wired backup systems for safety, and the cranes have monitoring systems designed to trip the system in the event of an emergency.

Three independent braking systems can be employed on the main hoists, with one set acting on the rope drum in an emergency. In addition to the hard wired back up systems, additional safety features also include accurate load monitoring. The basic structure of the cranes remains but will be specially strengthened to meet new standards and to provide a robust safety. However, the cranes will have new trolleys, cabins and all new electrics; long and cross travel drives, hoists and controls. Not forgetting a new coat of paint, also part of the contract. The cranes are designed to industry standards but will withstand extreme seismic, temperature and wind speed hazards.

All five cranes will be ready by end 2006 early 2007 with construction being a staggered process with the smaller B type cranes currently being commissioned with final hand over at Christmas 2006. The upper A cranes have a 58.84 metre span with double 75 tonne trolleys and drivers cabins, weighing approximately 310 tonnes. The lower B cranes have a 57 metre span with single trolleys and no cabins and weigh approximately 105 tonnes. They are all Monobox or torsion girder cranes. The trolleys are so designed that the units will not detach itself from the girder in the event of a fault condition including a seismic occurrence. BAE Systems vertical build system has accelerated the whole process of building submarines and means the cranes can be used in much wider applications. Both A and B type cranes are used for vertical fitment.

Close co-operation is essential and Jim Strathie, the Senior Project Engineer in charge of the project spends four days a week in Barrow as part of the continual monitoring process. This close cooperation between BAE Systems and KONECRANES UK has been critical in a project of this magnitude. BAE Systems have employed two consultant companies assigned to the project to undertake the structural design. Both companies have concentrated on both time constraints and project management. BAE Systems were anxious to update crane technology in assembly areas. For example, KONECRANES UK’s DynAHoist inverters were examples of the modern and precise control technology to be employed, along with specially designed micro drive units for special lifts due to the high lifting height being required, (it takes 10 minutes to cover 2 metres – 3 hours from floor to ceiling, so some components are being specially developed i.e. micro drive system which is remotely selectable). Along with the addition of KONECRANES’ DynAC inverter control on the travel and traverse motions, rewiring and other related changes have been done. A lot of other work has been in structural area of the cranes involving extra retention and stiffening.

KONECRANES UK is constantly developing their knowledge of cranes for the nuclear industry. Such specialist knowledge gives the group a distinct advantage when working on specialist projects in the future. The contract has to meet Construction, Design and Management regulations. This is challenging in terms of health and safety due to working in an operational construction hall and at height. KONECRANES’ quality systems were audited by BAE Systems but revealed no significant weaknesses. Following a rigorous QA process of approval, KONECRANES UK is now on the preferred suppliers list. KONECRANES UK will have to satisfy the directorates of the Health and Safety Executive including the Nuclear Installations Inspectorate before the cranes can be used for nuclear purposes. BAE Cranes Safety Case and Design Manager, Phil Foley says “This is a very dynamic project and it has been a challenge to incorporate all the design requirements within the timescale allowed. A massive amount of cooperation is needed to reach the mutual goal. Regular, daily, sometimes hourly dialogue is the order of the day so that there are no surprises and problems are dealt with ASAP. Communication, although informal, has been regulated. Face to face weekly and monthly meetings are conducted with the whole team coming together every month.” Ian Gowans, Nuclear Facilities Design Authority at BAE Systems says “KONECRANES UK experience in specialist crane construction is second to none.” Graham Kirkwood, Modernisation Group Manager, adds the comment: “This has been really useful for KONECRANES UK as it affords young designers a valuable learning experience.” Emphasis moves from design to installation early this year for final staged handover later. This is KONECRANES British unit’s biggest single refurbishment contract order.