Modernizing hydropower: Crane upgrade at Fortum's Imatrankoski plant

Hydropower is a cornerstone of Finland’s energy production, providing renewable energy and essential load-following power to meet changing demand. As society becomes increasingly electrified, the demand for carbon-free power continues to grow. Fortum’s Imatrankoski power plant, located on the Vuoksi River, is Finland’s largest hydroelectric facility. Maintaining the uninterrupted flow of this low-emission energy requires precise long-term planning. At Imatrankoski, a crane that has been in operation for nearly a century remains vital to essential maintenance operations.

Hydropower in energy production

The red-brick Imatrankoski hydropower plant on the shores of Vuoksi has been in operation for almost a hundred years. Since 1929, the turbines have delivered electricity to households, businesses, and industry. Today, the plant produces around one terawatt hour of clean energy annually.

"Hydropower plays a key role in stabilizing the Finnish electricity grid," says Fortum's Asset & Contract Manager Erkki Luukkonen. "If there is a disruption in the production or transmission of other forms of energy, hydropower as a load-following power generator quickly balances energy demand. This flexibility is invaluable."

The role of cranes in power plant maintenance

Seven large turbines run and hum around the clock inside the plant. When maintenance is required, the crane's lifts must be accurate and reliable.

"The Imatra plant has seven power units, each generating 20 to 40 megawatts," says Luukkonen. "During major maintenance, entire machines have to be replaced. That's when cranes become indispensable. They must be available when needed and accurate enough to handle small and heavy components."

The original crane system installed almost a century ago had worked well but had reached the end of its useful life. Konecranes conducted a detailed assessment to find the most sensible solution—modernization or installing a brand-new crane.

Modernization in the conservation of a historic building

"Fortum wanted to evaluate whether modernization or a complete crane replacement would be a better option. Due to the plant's historical significance, the decision was made to modernize. The decision simplified the installation and allowed us to preserve the key structural elements," says Jussi Latvala, CRS specialist at Konecranes, describing the initial project experience. The condition of the old crane and track was assessed through a crane reliability study, steel structure analysis, and RailQ runway survey.

Petra Väisänen, Project Manager at Fortum, adds, "Replacing the cranes completely would have required structural changes to the plant, which was not ideal. Instead, modernization allowed us to maintain the hall's historic integrity and improve the cranes' performance."

The project involved installing two 87-ton SMTs on the main crane and two 10-ton CXTs on the auxiliary crane. Konecranes installation engineers also upgraded all electrical systems, including control panels, load displays, and safety barriers. The mobile wheels and power supply were also replaced. The only remaining original component, the steel bridge structure, is a visible link to the crane's long history.

The modernized crane blends in with the historic building thanks to the retained steel frame.

Crane in a historic turbine hall

The modernized crane blends seamlessly into its surroundings, illuminated by the ample light streaming through the turbine hall’s large windows. Its retained lattice structure fits in with the hall's historic character, although the crane now incorporates modern technology for greater precision and safety.

"We kept the visible parts of the crane, such as the steel bridge, and made sure they matched the historic architecture," says Miitri Suhonen, Project Manager at Konecranes. "At the same time, the internal components were completely upgraded to ensure safety, accuracy, and reliability."

As the crane moves with the slight movements of the operator's fingers on its rails, it operates efficiently and in a controlled manner. The combination of modern systems and historic design combines decades of engineering expertise.

Read more about Konecranes' offering on:

• Crane modernization
• Industries: Power