Energy chain system for shipyards: Fast and safe conversion at a height of 122 metres

Profile

• What was needed: Harnessed energy chain including installation service
• Requirements: Proven solution with existing references worldwide, everything from a single source and with a long-term guarantee; functioning, low-maintenance and fail-safe cable management system
• Products: 5050RHD roller energy chain, heavy duty guide trough system made of stainless steel, chainflex TPE cables
• Industry: Shipyard, offshore wind power
• Success for the customer: Very quick conversion with a qualified assembly team, individual complete solution through engineering, installation and commissioning, everything from a single source ready for use within six weeks, functioning, low-maintenance, fail-safe cable management system.

About the application:
The Navantia shipyard manufactures and repairs civil ships and wind power projects. The shipyard in Puerto Real has one of the largest docks in the world. It has a shipbuilding capacity of up to 500 metres in length and two of the largest gantry cranes in Spain. The employed Goliath cranes work at a height of 122 metres. They each have a lower trolley with a 168-metre travel and an upper trolley with a 170-metre travel.

The challenge

After 40 years of operation, the old Goliath cranes needed repairs. The previous cable tender system was completely outdated and susceptible to corrosion, and the cables also had breaks and corkscrews. The maintenance effort increased continuously and critical security deficiencies became apparent. A prompt conversion was therefore absolutely necessary. With the shipyard's focus on all types of ships and offshore wind turbines, the system change had to be completed within six weeks. It had to be installed within 10 days.
Navantia had high demands on the new system: a proven solution was expected that would ideally be supported by global references. In addition, everything should be offered from a single source and with a guarantee. The seawater-resistant energy supply system had to guide the cables safely and be low-maintenance and fail-safe. Due to steel construction tolerances, a lateral compensation of the guide trough had to be provided. In addition, an additional load of 13kg/m, a speed of 0.5m/s and an acceleration of 0.3m/s² had to be taken into account.

Solution

With our worldwide company network, we were able to face these challenges. The local subsidiary worked closely together with our engineering team. Together with the customer, we developed an individual solution. The goals were clearly defined: the new system had to be low-maintenance and fail-safe, and it had to have the longest possible service life. To achieve this, heavy-duty roller energy chains of the 5050RHD series including a heavy-duty guide trough system made of stainless steel were used. A floating moving end was installed to laterally compensate for track tolerances. The developed system works with large temperature fluctuations of 5 to 50°C, with weather fluctuations and with high humidity. Greater system safety has been implemented so that nothing can fall from the crane. High-quality chainflex TPE cables were used to match the energy chain system, such as CF340, CF9, CF11 or CFLG.
In addition to the technical specifications and requirements, the installation service carried out its task according to the customer's strict timelines. The entire system was replaced within six weeks. The installation itself took no longer than 10 days.
We were able to thoroughly convince the customer with the solution. The system represents a significant technical improvement and the professional installation service meant that deadlines could be met.