dear reader, we have prepared this, the 19th issue of our popular customer magazine in exciting times: stahl cranesystems has found its feet and is now an established, important member of the columbus mckinnon family. in recent months, which have been packed with activity, we have continued to supply our products to the usual high standards and have completed many attractive projects with our partners throughout the world. to give you few examples, we are presenting some of our global projects in this magazine. whether it is in the heat of africa or in icy finland, our “made in germany” products bear witness to the quality and outstanding technical expertise of our staff, from distribution through manufacturing to shipping. we would like to thank you for the confidence you have shown in us and for our good working relationship! yours dr. thomas peukert content usa interview with mark morelli page 03 page 22 cranes for the us motor industry customer sales meeting page 23 brazil unique test centre page 21 germany training and studying – interview with natalie müller report from künzelsau: training page 12 page 14 i want to ride my bicycle! page 20 page 21 professional development worldwide logimat 2017 page 21 page 18 nigeria advanced technology brings success south africa piecework exchange page 22 page 10 finland even in the cold a blast can happen estonia page 09 green power russia page 17 natural gas for nutrition page 21 elektrotaschkran czech republic page 20 synchronised movement page 04 page 22 page 23 mechanical engineering fair in brno malaysia professional development worldwide india there’s more than silk in kashmir united arab emirates the fastest stahlites page 20 spain cranes for 3d measuring device page 23 publisher stahl cranesystems gmbh, daimlerstr. 6, 74653 künzelsau, germany editors thomas kraus, heike metzger, clara ketterer, daniela peuckert design visuell studio für kommunikation gmbh, stuttgart printing raff holding gmbh, 72585 riederich copyright stahl cranesystems gmbh, 2017. all rights reserved. reproduction, including extracts, only with written permission from the publisher. no liability assumed for errors.

there’s more than

>>>a stationary shw 8 winch with a safe working load of 2 × 60,000 kg consisting of two rope drums and a gearbox. after completion was 21.5 m at 2 × 150 m rope length. the kishanganga hydroelectric power plant lies 2,400 metres above sea level. at these altitudes, temperatures from november to may are icy cold. in the summer months, by contrast, landslides make the region difficult to access. not least for these reasons, the customer nhpc ltd. sought strong partners able to guarantee punctual delivery and reliable execution of the work. dsd noell gmbh from würzburg and stahl cranesystems from künzelsau stood the test of these high requirements. to ensure continuous operation of the turbine generators of the kishanganga hydroelectric power plant, which are meant to generate a total of 330 megawatts of electricity, it is vital that a continuous flow of water is ensured. the plan to guarantee this: to dam the kishanganga river. as a specialist in the field of hydraulic steel structures in water- ways, weirs and hydroelectric power stations, dsd noell gmbh planned and built a 37 m high weir. stahl crane- systems, a specialist in crane technology with the largest range of highquality hoisting technology available worldwide, developed and delivered the winch system to lower the 100 t sluice. the demands on the hoist were high as it had to work reliably in the adverse environmental conditions in the mountainous region. the first concepts for the custom so- lution were developed at the headquarters of stahl crane- systems in künzelsau back in 2009: a stationary shw 8 winch with a safe working load of 2 x 60,000 kg consisting of two rope drums and a gearbox. to ensure equal distri- bution of the weight, the hoist was designed in reeving of 2 x 12/2-1 and the drum manufactured in a length of l4. the final height of lift achieved after completion was 21.5 m at 2 x 150 m rope length. thanks to double symmetrical arrangement of the reevings, it was possible to realise perfect synchronism of the two load hooks. the total length of the winch system covers almost 9 m. the rope drums are flanged to the gearbox with special couplings, thereby compensating all tolerances between the machine and steel structure. due to local conditions, the gear motor is mounted vertically. as a result of this unusual assembly, the hoist motor is mounted above one of the two rope drums. to ensure safe lowering of the sluice, the engineers from stahl cranesystems implemented the rope with seven- fold safety. in addition to that, they included a second brake in the winch system as safety brake, flanged directly on to the gearbox. the hoist was equipped with an overload cut-off device for each of the two load hooks and place- ment of the load realised separately through slack rope cut-off for each of the two hooks. both of the current hook positions are shown as optional extra on a display on the switch cabinet doors. in addition to that, the motor currents of the hoist motor are shown on ammeters. this hoist motor is additionally protected by motor circuit-breakers. the hoist is designed for its application for an ambient temperature between –25 °c and +40 °c. robust, pole- changing technology with further tolerance ranges enables operation in unstable mains power supplies. an external ventilation with stopping control was implemented in the hoist motor to ensure a 15-minute duty for the hoisting technology with a subsequent cooling phase. the winch system was given a special finish of a 270 µm thick top coat of polyurethane to make it weatherproof. due to the air humidity, stahl cranesystems also equipped the panel boxes and hoist motor of the individual hoists with a heater. a hoist brake with built-in brake venting lowers the load with pauses in the event of a power failure. the weight of the load is determined continuously by the smc multi- controller via analogue measuring sensors. in the case of an overload, the lifting movement is switched off imme- diately. the multi-controller can, moreover, measure further data such as, for example, the load spectrum, the operating time, the full-load operating time and the motor switching operations and read them out with the help of a pc.

>>> construction work on the kishanganga river had almost been completed at this time: the weir, which passes a part of the river into a newly constructed riverbed, was built in autumn 2016. the remaining water is used to supply the hydroelectric power plant continuously. it is first collected from the reservoir in an equalizing reservoir through a 24-kilometre long tunnel before it is passed to the underground power station with three pelton turbines. each of the turbines generates a power of 110 mw. the crane system was commissioned on site by the stahl cranesystems factory service centre. since the passes in the himalayas are only passable for a few weeks in summer, the equipment had to be delivered in a finely defined period of time. the moment came at long last in mid-july this year: the sluice was lowered with the help of the special winch. since then, the reservoir has been filling up day for day. the minimum draw down level (mddl) was already reached in mid-august. the kishanganga hydroelectric power plant is set to go online in 2018. despite delays due to the impassable terrain and unrest in the nearby border to pakistan, all companies involved in the project and the customer nhpc ltd. are satisfied with the progress in this project, which represents a further step in the development of the region jammu and kashmir. with the kind support of uwe trenkmann/dsd noell gmbh, robert seibold/haslinger gmbh metallbau, gerhard deitigsmann/stahl cranesystems gmbh the protective enclosure of the hoisting technology from stahl cranesystems was manufactured by its certified partner haslinger gmbh metallbau + krantechnik. the dam in august 2017: the water level rose to the minimum draw down level (mddl) within a month.

even in the cold a blast can happen explosion-proof hoisting technology on the coast of finland as one of the first and for a long time also one of the only manufacturers to do so, stahl crane- systems has been developing explosion-proof hoisting technology since the end of the 1920s. much has happened since then technically – but nothing has changed regarding the mode of action and importance of explosion protection. with its roots in mining, the explosion-proof tech- nology from stahl cranesystems is used in many branches of industry nowadays: among others in the chemical and petrochemical industries, the shipbuilding and offshore industries as well as the power supply industry. in explosive atmospheres, the electrical devices used here are potential sources of ignition. inflammable gaseous substances can in combination with oxygen cause a sudden chemical reaction – or explosion – when exposed to a single spark. if the risk of explosion is very high, only explosion-proof equipment may, according to international safety guidelines, be used. stahl cranesystems offers one of the world’s most comprehensive product portfolios in explosion-proof hoisting and crane technology. use in finland: explosion protection in icy cold in 2015 the experienced engineers of stahl cranesystems took on the challenge of developing an lng maintenance crane for use on the icy coast of finland. the first finnish lng tank began service in the port and industrial city of pori in march 2016. the slewing crane on the tank comes into use whenever the pump needs to be lifted out of the lng tank and serviced. this happens up to five times a year. the pump, which pumps the cold liquefied natural gas (–164 to –161 °c) in a pipe system, must then be lifted out of the approximately 35 metre high tank into the open for maintenance work. in view of the extreme conditions in the tank, special ropes, which are fastened permanently to the liquefied natural gas pump and therefore spend their lives in the tank, are needed for this. when maintenance work needs to be carried out, these ropes are fastened to the rope drum and hoist. stahl cranesystems uses a slewing crane of the type “boss exn 32–16” (vetter krantechnik) for this. a modified sh 50 ex wire rope hoist with a lift of 46 metres is used as hoist. the “light lng slewing crane” is a development by stahl cranesystems spain, which can under certain circumstances (as in the lng terminal in pori) represent an alternative to the classical lng hoists. the subsidiary has built four such cranes together with vetter since 2005 – in addition to the numerous smaller slewing cranes that vetter delivers to spain every year.

report from künzelsau training and studying with the world market leader interview with natalie müller, training & development officer at stahl cranesystems do you remember starting at stahl cranesystems? how did your training work and which departments did you get to know? i still remember starting here in künzelsau very well. when i started my dual study course in industrial business administration in september 2009, the traditional introductory days were held first. we spent three days camping together in kocherstetten so that we could get to know each other better and grow together as a team. this type of introduction to a new phase in life has proved successful, which is why we have continued this at stahl crane- systems until today. how did things continue after the training for you? we were able to concentrate on focal areas while we were still studying. after talking with the personnel and training manager, i was pleased to be able to choose “organisation and personnel”, which has potential for the future. after graduating in 2012, i was then taken on as a personnel officer initially. since 2014, i have been working as a training and development officer, dealing with training and professional development at stahl cranesystems. women are mostly in the minority in the technical professions. what attracted you to the crane industry? it was my family that drew my attention to stahl cranesystems. like me, my brother also did his dual study here a few years ago, although his course was in mechanical engineering. the things that he talked about also awakened my interest in stahl cranesystems as a company and in the crane industry. stahl cranesystems has a long tradition as a training company. why is the training considered to be so valuable? for us, training in the künzelsau plant has a good reputation and a long tradition. it is important for us to be able to train qualified, motivated new recruits so that we can continue to operate successfully in the market now and in the future and

report from künzelsau starting work with curiosity training at stahl cranesystems at stahl cranesystems in künzelsau, between 5 and 10 young people a year start training to become electronics technicians, industrial elec- tricians or industrial mechanics. in the dual training system, which is recognised worldwide, stahl cranesystems provides both practical and theoretical training for the young people. application-based phases in the company are supplemented by academic teaching, thus cre- ating a sound knowledge base. the company has been reaping the benefits of the successful training of these young employees for a while: the most of the trainees at stahl cranesystems start their career here. training marks the start of a new phase in life. this is the case for a number of young people at stahl cranesystems every september. suc- cessfully training young employees is extremely relevant in the künzelsau plant. particular at- tention has been paid for many years to making the training period as interesting and varied as possible. this year, on 4 september 2017, 8 new trainees and students were once again welcomed to stahl cranesystems. it isn’t easy deciding on a future career after school. everyone has to select from the many options available and find their own individual path. as a medium-sized company and international specialist in explosion-proof crane tech- nology, stahl cranesystems supports young adults in making this decision. with a wide range of apprentice- ship and study options, the company offers the possibility of trying out and learning a variety of careers. by completing a placement at stahl cranesystems, school pupils and students can gain initial career experience and an insight into the work of a globally operating company. placements are possible here in all the careers requiring training: industrial mechanics, electronics and industrial electrical systems. for some years now, stahl cranesystems, together with five nearby companies, has been involved in the joint training initiative known as the “gabi initiative”. gabi (from the german “gemeinsame ausbildungsinitiative”) networks the ap- prentices in the participating companies, so that premises, machinery and equipment can be shared. this means that the apprentices can tackle interesting tasks together in inter-company project teams and expand their know- ledge and experience beyond the bounds of the individual company.

russia moscow mendeleyevsk natural gas for nutrition hoists from stahl cranesystems in the world’s third-largest fertiliser factory at mendeleyevsk in the russian republic of tatarstan, 1,000 kilometres east of moscow, the new ao industrial complex “ammonium” was inaugurated in early 2016. the chemical plant produces urea, ammonium nitrate and nitrogen fertiliser for industrial agriculture as well as methanol as a raw material for the petrochemical industry. companies from russia, japan and china were involved in the design and construction of the plant. the crane technology for maintenance of the plant stems from stahl cranesystems in künzelsau. not everyone immediately thinks of food when talking of energy from natural gas. methane, however, is not only used as a fuel gas, but is also an important raw material for the syn- thetic production of ammonia – from which, in turn, most fertilisers are made. without them, a large part of today’s world population could not be fed. russia, next to the usa, has the largest gas deposits worldwide and a growing interest in diverse exploi- tation of its natural resources. it was therefore decided in 2010 to build the

advanced technology brings success maintenance cranes for dusty environments in 2012, large cement plants were built in the cities of obajana and ibese in the south of nigeria. both were equipped with crane systems and hoist- ing equipment which, however, can no longer guarantee safe processing capability just two years after installations. the maintenance cranes, like the entire production plant, were not reliable enough for the regular mainte- nance of the cement plants, resulting in constant delays. on the search for a reliable partner for the replacement of the crane system, the nigerian cement manufacturer came across stahl crane- systems in künzelsau.

synchronised movement adamec crane systems, czech republic the iveco bus factory in vysoké mýto is the largest bus factory in the czech republic, with over 3,100 employees. in the welding plant, 10 cranes with lifting capacities of 2 x 1,600 kg each are used in various manufacturing areas. two cranes, each with two shf wire rope hoists are used in tandem to lift and move a complete bus. the four hoists are fitted with an intelligent crane control system to ensure synchro- nised lifting of the load. the fastest stahlites stahl cranesystems fze, dubai the 30,000 participants in the dubai marathon included some of the staff from stahl cranesystems fze along the 10 km course once again this year. the fastest runner was awad ibrahim with a fantastic time of 01:00:06 hours, shortly followed by managing director werner wagner, who finished in 01:04:09 hours. congratulations on this sporting achievement! i want to ride my bicycle! stahl cranesystems gmbh, germany in august, 8 employees of stahl cranesystems in künzelsau made use of the lovely summer weather to take a little exercise. from the meeting point at waldenburg station, they set off on mountain bikes for a 30 km tour at a height of 410 m. guaranteed biking fun for all!

slt components s.r.o. czech republic reliable for the us motor industry mt. clemens crane, usa the international mechanical engi- neering fair in brno, czech republic, is the leading industrial trade fair in central europe. all the key areas of the mechanical engineering industry are represented, divided into nine specialist product areas. 9– 13 october 2017 the faurecia automotive supply com- pany in fraser, michigan, supplies motor manufacturers in the detroit area on a just-in-time, 24/7 basis. sev- eral double and single girder over- head travelling cranes are used here for equipping and maintaining the presses for stamped sheet metal parts. our partner, mt. clemens crane, sup- plied the cranes with as 7 wire rope hoists with varying lifting capacities which work reliably and durably in tough operating conditions. piecework exchange stahl cranes and hoists, south africa >>> two as wire rope hoists worked reliably for 22 years on a thyssenkrupp portal scrape in the goedehoop mine in the province of mpumalanga, south africa. as part of the modernisation of the plant, the two as wire rope hoists were to be replaced in autumn 2016 by new sh wire rope hoists – without any break in production. together with thyssenkrupp and anglo american coal, the operating of the plant, our partner, stahl cranes and hoists (pty) ltd agreed on the best time for the installation of the new wire rope hoists. the installation team worked continually day and night one weekend and, despite one or two challenges, completed the entire alteration of the plant within just three days. both the installation devices on the portal scrape and the electronics for the new wire rope hoists had to be replaced and adjusted. after testing and commissioning, the modernised system was handed over to the satisfied customer and was fully function again on the monday. each of the two wire rope hoists is installed on one of the arms of the portal scraper, with a lifting capacity of 6.3 t. the new sh wire rope hoists will also be constantly exposed to the effects of the environ- ment and have to withstand rain, wind, dust and heat – until they are next modernised.

e d . l l e u s i v 0 8 4 0 0 9 9 . r n - h c a s y n a m r e g n i d e t n i r p fax to +49 7940 128-2300 information literature copy, fi ll in, fax company name address telephone department mail you can find this and other brochures at www.stahlcranes.com/download we will gladly also send them to you by post. the st chain hoist the sh wire rope hoist the as 7 wire rope hoist crane technology sr wheel block 4 1 0 2 . 0 1 4 1 0 2 . 3 0 7 1 0 2 . 3 0 7 1 0 2 . 8 0 7 1 0 2 . 3 0 der kettenzug st umfang: 28 seiten en nl cs es no ru de fr pt zh der seilzug sh umfang: 24 seiten de fr cs en nl ru es pt zh der seilzug as 7 umfang: 28 seiten de fr ru en nl zh es pt die krantechnik umfang: 28 seiten de fr ru en nl zh es pt der radblock sr umfang: 8 seiten en es de fr expertise in explosion protection the lng engineering solution 2 1 0 2 . 0 1 5 1 0 2 . 5 0 komp. im explosionsschutz umfang: 28 seiten die engineeringlösung lng umfang: 16 seiten de fr ru en nl zh es pt no de fr en ru es no presented by de: german, en: english, es: spanish, fr: french, nl: dutch, pt: portuguese, ru: russian, zh: chinese, no: norwegian, cs: czech www.stahlcranes.com stahl cranesystems gmbh, daimlerstr. 6, 74653 künzelsau, germany tel +49 7940 128-0, fax +49 7940 55665, marketing.scs@stahlcranes.com