Zero is the perfect score of zinc producer Padaeng Industries

One of Asia-Pacific's major zinc producers has achieved near zero downtime and breakdowns as a result of introducing a programmed maintenance agreement with the Konecranes group. Padaeng Industries of Thailand operates the only zinc smelter in South East Asia, with an annual production capacity of 110,000 metric tons of zinc metal and alloys, including special high-grade (SHG) zinc metal and value-added zinc alloys. "Cranes such as the CXT type used to lift metal from the cathodes and to feed material to the furnace are vital to our production 24 hours a day," said Padaeng Industry Vice-President ?Maintenance Mr. Pothong Pipatpaiboon. "We can抰 afford to have them go down. We require world class standards of reliability and safety." Konecranes has more than 373,000 cranes of all brands under service contracts worldwide, employing more than 9,600 people at more than 485 locations in 43 countries. This global experience is applied locally for Padaeng by Konecranes Thailand branch, under the direction of Service Branch Manager Jirapong Kocharack. "We originally met Konecranes when they came on-site as a contractor. We drew on their experience to prepare our yearly inspections. We tried them out and they were very strong, terrific," said Pothong. Konecranes role for Padaeng subsequently broadened to cover maintenance of all cranes at the site in Tak province, which employs 550 people in an operation that prides itself on optimum standards of safety and efficiency. "The main thing about Konecranes is that their standards of reliability and quality are very high. After Konecranes came into our plant from 2003 the numbers of breakdowns dropped lower and lower to the point where we now achieve practically zero breakdowns and zero downtime from cranes that are serviced by them. And besides the service aspects, they also assist us with upgrades where required and all upgrades since 2003 have employed Konecranes equipment, which has been outstanding." One major modernization project in which Konecranes was involved was the upgrade of two zinc cathode cranes. Padaeng wished to ensure that these vital cranes did not have their ongoing reliability compromised by their very harsh operating conditions. At the same time, Padaeng wanted to increase plant capacity, with the new 8-ton two-speed hoists replacing the old 6.3 ton hoists with single speed hoisting motors. "We installed new hoisting machinery that would achieve the required speed with the heavier load. We also enhanced safety with a new limit switch package to ensure accurate positioning of the loading device," said Konecranes' Jirapong Kocharack. "To further ensure safety and reliability, the existing crane structure and runway was carefully inspected and recalculated for the new loadings." The hoisting machinery for the crane's frame was factory assembled and tested, to minimize on-site erection time. No aluminum parts were used. The cast iron motor frame and machinery frame were especially painted to resist the aggressive environment. Robust shoe brakes were fitted. "Site work was completed for the first crane in just 36 hours and the second one in just 18 hours," said Jirapong. "The erection team was thoroughly briefed before going on site, so as to achieve minimal installation time."(finished)Adidas Adilette Slides