Industries

Coal-fired power plants generate electricity through the following steps:

1. Burn coal and heat purified water in a boiler to produce steam.
2. Use the steam to drive a propeller-shaped turbine.
3. Rotate a generator directly connected to the turbine to produce electricity.

The photo shows a load test conducted on-site in Japan when an ER2SG 20-ton electric chain hoist with manual trolley was delivered for turbine installation and maintenance.

Turbines are extremely large, heavy, and highly valuable pieces of equipment. For this reason, they are transported in multiple parts and carefully assembled on-site using the ER2SG.

The ER2 series features a highly reliable electromagnetic brake, a friction clutch to prevent overload, and a unique nickel-plated chain resistant to rust and wear, ensuring safe and efficient handling of heavy loads.

Products Used:

Kito ER2 Electric Chain Hoists

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Modern coal-fired power plants improve power generation efficiency by cooling the steam that has passed through the turbine, converting it back into water with residual heat, and returning it to the boiler for reuse—a process known as steam recycling.

At a power plant in Germany, CB chain hoists are used in the cooling water pump room, which circulates cooling water, to perform maintenance on large motors that drive the pumps. These motors operate continuously in high-temperature environments, making them extremely expensive and heavy. As a result, maintenance work requires exceptional safety and ease of operation.

CB chain hoist delivers outstanding performance with approximately 80% mechanical efficiency—far surpassing competing products—and features a unique mechanical brake for added safety. Backed by a proven track record of global adoption, the CB was chosen for its reliability under demanding conditions.

Products Used:

Kito CB Manual Chain Hoists

Project Gallery:

In coal-fired power plants, numerous pipes run throughout the facility to generate electricity—such as main steam pipes that deliver high-temperature, high-pressure steam to the turbine, and feedwater pipes that return water from the condenser to the boiler.

At a power plant in Indonesia, Radiolink Plus was used to measure the load of a cylinder that forms part of the piping during maintenance work. Accurate load measurement was essential to ensure safe and efficient crane operations in the plant’s limited space.

Radiolink Plus allows wireless, real-time measurement from up to 1,000 meters when using the Handheld Plus, or up to 100 meters with the dedicated app. This capability was highly valued by the maintenance team, enabling them to complete the work safely and successfully.

Crosby G-2130 Bolt Type Shackles were installed between the crane hook and the synthetic sling, positioned above and below the Radiolink Plus to support load measurement. These shackles, featuring high corrosion resistance thanks to zinc plating and having passed rigorous fatigue tests, are ideal for coal-fired power plants where steam-induced corrosion and vibration fatigue are concerns.

Furthermore, with an industry-leading safety factor of 6:1, they ensure secure lifting of heavy cylinders. Combining reliability and safety, Crosby products provide peace of mind even in the most demanding environments.

Products Used:

Crosby Straightpoint Radiolink Plus (RLP)

Crosby G-2130 / S-2130 Bolt Type Anchor Shackles

In coal-fired and nuclear power plants, the process begins by heating purified water in a boiler to produce steam. This steam flows from high pressure to low pressure, driving the turbine. After passing through the turbine, the steam is thoroughly cooled to reduce pressure, which improves power generation efficiency.

When drawing cooling water from a river, screening—removing debris and foreign objects—is an essential step to protect cooling pumps, piping, and other components of the cooling system.

At a coal-fired power plant in Germany, multiple ER2 electric chain hoists have been adopted for lifting and lowering screening equipment. ER2 features a unique nickel-plated chain with excellent corrosion and wear resistance, and is equipped with a highly reliable electromagnetic brake—the same technology used in industrial robots. These features ensure safe operation even in outdoor environments, contributing to stable and efficient cooling system performance.

Products Used:

Kito ER2 Electric Chain Hoists

Project Gallery:

The combined cycle power generation system is one of the most efficient methods within gas-fired power generation. First, electricity is generated using a gas turbine. The high-temperature exhaust heat produced during this process is then used to create steam, which drives a steam turbine to generate additional electricity. By producing power in two stages from a single fuel source, energy is utilized with minimal waste.

At a gas-fired power plant in Japan, large-capacity CB chain hoists were used for precise alignment during the installation of the steam turbine casing. Because the casing holds high-pressure steam, it is thick and weighs approximately 30 to 50 tons, requiring careful handling to avoid damaging the turbine beneath it.

CB chain hoist, featuring an impressive mechanical efficiency of about 80%—far surpassing competing products—and an exclusive mechanical brake, was selected thanks to its long-standing track record in the power industry. This ensured a safe and efficient installation process.

Products Used:

Kito CB Manual Chain Hoists

Project Gallery:

Courtesy of the official Solar Turbines website

Gas-fired power generation serves multiple roles, including acting as a “peaking power source” that supplies electricity only during periods of high demand, and as a relatively small-scale “distributed power source” that provides electricity close to demand centers.

In the United States, during maintenance of these gas turbines, SHB (a CB model designed to minimize the product’s vertical clearance) with a 16-ton capacity is used for lifting turbines. To enable safe lifting even in confined spaces, the design—including the trolley system—is customized to meet customer requirements, ensuring stable and efficient maintenance operations.

Products Used:

Kito CB Manual Chain Hoists

Nuclear fuel that has completed its role in a power plant continues to emit strong radiation, so it must be properly stored to minimize radiation exposure.

Typically, immersing the fuel in water at a depth of about 6 meters (approximately 20 feet) provides sufficient shielding, reducing radiation to a level where work can be performed without wearing special protective clothing.

ER2 inverter(VFD) features a “smooth start and stop” function to reduce load sway and incorporates a highly reliable electromagnetic brake that surpasses competing products. These features support the safe removal and storage of spent nuclear fuel—tasks that require the utmost care—contributing to the safe and efficient operation of nuclear power plants.

Products Used:

Kito ER2 Electric Chain Hoists

Project Gallery:

Photo Source: https://www.iter.org/

Nuclear fusion power is a next-generation technology that generates electricity using the same principle as the sun. It produces no carbon dioxide during operation, and even in the event of an accident, the reaction naturally stops, making it highly promising for safety.

Although currently in the research and demonstration phase, it is expected to become a key solution for stable power supply, decarbonization, and energy security in the future.

At an experimental reactor in France, it was necessary to check the load balance when installing a “thermal shield” to prevent the component from tilting. This thermal shield is an enormous part with a diameter of approximately 20 meters and a weight of about 50 tonnes, yet its thickness is only 10 millimeters, making it extremely delicate.

To ensure safe handling, 16 Compound Plus units (Radiolink Plus specialized for PC-based load monitoring) were installed on the lifting gear, and the PC application Insight was used to perform real-time, remote, simultaneous load measurements. This allowed the center of gravity of the load during crane lifting to be identified instantly—a feature highly valued by the customer—and contributed to safe and efficient installation work.

Products Used:

Crosby Straightpoint Radiolink Plus (RLP)

Project Gallery:

Hydropower generation uses the force of water stored in a dam, which flows downward with great velocity due to the height difference, to rotate a turbine resembling a propeller. As the turbine rotates, it drives a connected generator to produce electricity.

The Kaplan turbine, commonly used in hydropower plants, is a propeller-type turbine equipped with variable-pitch blades, making it ideal for low-head, high-flow water sources. The blade angle can be automatically adjusted based on water flow and water level, maintaining high generation efficiency while enabling flexible operation in response to changing dam conditions.

While this design enables highly efficient power generation, it also involves many moving parts and a complex structure, making regular maintenance essential. CB chain hoists safely and efficiently lift blades during maintenance work on variable-pitch blades, which can weigh over 10 tons each in large models, thanks to their unique mechanical brakes and approximately 80% operational efficiency that surpasses competing products.

Products Used:

Kito CB Manual Chain Hoists

Project Gallery:

In wind power generation, turbines are becoming larger to improve efficiency and reduce costs. As a result, installing massive blades and removing them during maintenance or dismantling has become increasingly challenging, especially due to wind effects.

Crosby Airpes Yoke Blade Clamp, with its unique tilt system, compensates for blade inclination caused by wind and for changes in the center of gravity when removing damaged blades. This keeps the blade level, ensuring safe and reliable operations.

Products Used:

Crosby Airpes Yoke Clamp

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In wind power generation, the gearbox is a device that increases the rotational speed of the blades, which turn at low speed, so that the generator can efficiently convert energy into electricity. Because gearboxes weigh several tons, mobile cranes are used for installation and replacement work.

Gunnebo Industries GrabiQ delivers outstanding performance in heavy lifting operations. When lifting large, heavy gearboxes with a crane using a four-point sling, GrabiQ offers unique advantages over other chain slings.

With the Grab Hook OG, you can quickly adjust the length of each chain simply by hooking it in place.

Additionally, the Safety Hook BK features a trigger embedded in the body, preventing snagging or damage and ensuring the latch does not accidentally open.

These features enable efficient and safe gearbox installation work.

Products Used:

Gunnebo Industries Grade 100 Welded Master Link Assembly MT

Gunnebo Industries Coupling link G

Gunnebo Industries Grab Hook OG

Gunnebo Industries GrabiQ Chain KLA, Grade 10 (200)

Gunnebo Industries Safety Hook BK

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The inside of a wind turbine nacelle is extremely narrow, making it impossible to use cranes or large lifting equipment directly.

This is where LB and LX lever hoists come into play. Lightweight and compact, LB and LX can be mounted on beams or dedicated rails, making them ideal for precise positioning of gearboxes weighing several tons within the limited space of the nacelle.

In an environment where safety is the top priority, LB and LX are chosen for their proven track record worldwide and their superior durability and reliability compared to other products, ensuring loads are securely held. Because gearboxes have irregular shapes and an offset center of gravity, multiple LB and LX units are used to maintain balance during installation.

Products Used:

Kito LB Lever Hoists

Kito LX Lever Hoists

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In terminal processing during transmission line installation and in repair work for damaged lines, “explosive welding,” which bonds metals together using explosive force, is widely adopted.

Explosive welding uses the power of an explosion to achieve instant bonding, enabling a more uniform joint compared to conventional crimping methods and allowing dissimilar metals to be joined. Moreover, because the process is completed in an instant, work time is significantly reduced, making it efficient even for high-altitude operations or under adverse weather conditions.

LB lever hoists are widely used to temporarily fix power cables during explosive welding. They combine robustness with a compact and lightweight design compared to other products, making them easy to handle during overhead work. Even when the chain is in free-running mode for length adjustment, their unique safety mechanism activates the brake under sudden load to prevent the load from falling. This ensures both safety and efficiency, making them an ideal solution for transmission line construction sites.

Crosby S-2130 Bolt Type Shackles also play an important role in temporarily securing power cables. They have passed fatigue testing at 1.5 times the rated load for 20,000 cycles and Charpy impact testing at -20°C, ensuring reliable performance even in harsh outdoor environments.

Products Used:

Kito LB Lever Hoists

Crosby G-2130 / S-2130 Bolt Type Anchor Shackles

Project Gallery:

Ensuring proper load monitoring during the construction of overhead powerlines is crucial for the safe and accurate installation of structural and electrical components.

Crosby Straightpoint Radiolink Plus, when paired with the included Handheld Plus hand controller, can monitor up to four load cells, simultaneously, ideal for complex lifting operations with multiple lifting points. For expanded functionality, it can also integrate with Insight software, enabling real-time monitoring of up to 126 Crosby Straightpoint wireless load cells on any Windows tablet or laptop.

By integrating this technology into construction workflows, teams can enhance safety, improve efficiency, and ensure compliance with industry standards.

Products Used:

Crosby Straightpoint Radiolink Plus (RLP)

Crosby G-2130 / S-2130 Bolt Type Anchor Shackles

Crosby Standard Wire Rope Thimbles

Kito LB Lever Hoists

Project Gallery:

Transmission lines are secured to towers through insulators, which act as electrical barriers to prevent leakage to the ground and reduce the risk of electric shock, ensuring safe power delivery.

LB lever hoists are widely used to temporarily fix power cables during insulator installation. Despite their compact and lightweight design, LB lever hoists offer exceptional durability compared to other products. They also feature a unique freewheel mechanism that allows safe and quick chain length adjustment even in freewheel mode, improving work efficiency.

Additionally, the optional Safety Locking Module provides a secondary safety system: if a hoist’s main brake fails, the Safety-Lock mechanism engages to prevent the load from falling. This dual protection enhances both safety and reliability on the job site.

Crosby G-209 / S-209 Screw Pin Anchor Shackles feature a screw pin design that allows for easy pin installation and removal. They are galvanized for superior corrosion resistance and have successfully passed rigorous fatigue testing. This makes them a reliable choice for demanding work on transmission towers, even under harsh environmental conditions.

Products Used:

Kito LB-SL Lever Hoist

Crosby G-209 / S-209 Screw Pin Anchor Shackles

Project Gallery:

The structural wire ropes supporting towers are constantly exposed to harsh climatic conditions throughout their service life.

These wires move continuously due to the effects of wind and rain, while also bearing constant load. To ensure safety and prolong their lifespan, regular tension inspections and adjustments are essential for guy wire maintenance on cell towers, flare stacks, antennas, and masts.

Crosby Straightpoint COLT is a wireless online tension meter that features an extensive wire rope database and enables fast, accurate measurement of tensions up to 5,000 kg (approximately 11,000 lb) and for wire ropes up to 25 mm (approximately 1 inch) in diameter.

Using Bluetooth, it allows for real-time tension measurement and recording via a dedicated smartphone app. Additionally, it automatically captures local weather conditions (temperature, wind speed, wind direction), and—when combined with GPS coordinate acquisition—enables logging of these reports directly on a smartphone.

Products Used:

Crosby Straightpoint Clamp On Line Tension Meter (COLT)

In countries such as the United States, Europe, and Japan, many transmission networks were built 50 to 70 years ago and are now severely aging.

These outdated facilities cannot adequately meet current energy demands, withstand extreme weather events, or support renewable energy integration. As a result, they pose risks of power outages and energy losses, making equipment upgrades essential.

LB lever hoists also play an important role in dismantling transmission networks. Their compact, lightweight yet robust design makes them ideal for work at height. During tower dismantling, they are used to maintain load tension while safely removing heavy components. Compared to other products, their superior load-holding performance provides workers with a sense of security.

In the third photo, you can see the dismantling of the tower on the right and the simultaneous installation of a new tower in the center, illustrating the ongoing process of infrastructure renewal.

Products Used:

Kito LB Lever Hoists

Project Gallery:

Railway companies receive high-voltage electricity from power utilities and convert it into the voltage and current suitable for train operations. To protect this equipment from risks such as lightning strikes, severe weather, and unauthorized access, substations are installed inside dedicated buildings.

In Japan, chain hoists are used to handle substation equipment that can weigh over 10 tons. First, a manual chain hoist CB is used to open and close the blue hatch. Then, an electric chain hoist ER2 lifts the equipment from the first floor to the fourth floor for installation.

ER2 is equipped with a highly reliable electromagnetic brake, as well as a friction clutch and upper/lower limit switches. These overload protection devices come as standard features, ensuring safe and secure installation of substation equipment.

Products Used:

Kito ER2 Electric Chain Hoists

Kito CB Manual Chain Hoists

Utility poles serve as supports to safely deliver electricity from substations to homes and buildings. They are equipped with wires, transformers, and switches to efficiently distribute electricity over roads and rooftops.

In the United States, during the manufacturing process, pipes and steel plates are rolled into a cylindrical shape to form the pole. When lifting these poles and immersing them into a zinc galvanizing bath for corrosion protection, Peerless beam clamps are used.

The photo shows a custom-designed beam clamp equipped with magnets to safely lift long poles, tailored to meet customer requirements.

Products Used:

Peerless Lifting Beams ALB

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